To keep you up to date and well informed about FNM

Thursday, 26th May 2011, "WE WANT YOU!" – Freudenberg NOK Mechatronics health program in Pécel (HU)

The Hungarian Government in collaboration with the European Community has announced a programme in 2011 to promote occupational health (TÁMOP 6.1.2.) in line with the new Széchenyi plans. One of the aims of this programme is to establish a long-term internal health programme in the company. For more information, please, use the link.

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Monday, 12th July 2010, Artikelveröffentl. aus der Website „Drivingvisionnews.com"

Freudenberg NOK Mechatronics (FNM), a joint venture between Freudenberg & Co. and NOK Corp., were founded in 2002. They are a development partner and a supplier of mechatronic solutions for the automotive industry and develop individual products with its flexible flat wiring materials and connecting technologies. Due to the integration of functionality such as antennas, switches, heaters, sensors and illumination there are several advantages compared to conventional solutions:

• Less space
• Weight reductions
• Flexible / individual design
• Enhanced quality by electrical interface reduction
• Easier assembly of sub-modules
• Cost-effective solutions

Core capabilities 3D CAD design 
With the launch of innovative LED light systems in mass production over the last couple of years the design of headlamps and rear lamps become more and more complex. Therefore, these applications require a fully software-based development process (with an interface to customers). 
With a consistent 2D / 3D CAD process a design rule check can approve the final product. Moreover, the assembly can be simulated in the CAD system, which helps to reduce the development time and save cost-intensive engineering changes.

Flex material 
The basis of lighting products is a FPC 
(Flexible Printed Circuit) laminated on an aluminum panel. The standard base material is a PEN foil (Polyethylennaphtalat) processed in cost-effective reel‑to‑reel processes.

For headlamp applications with higher operating temperature FNM has developed a high temperature base material (HT PEN) in cooperation with a partner. This new HT PEN material has a maximum operating temperature of 130°C, which covers most today's requirements for exterior lighting applications.

Connecting technologies
Lead-free soldering . 
Flex-on-aluminum with PEN base material has already been in serial production for 4 years. However, due to the directive on the restriction of the use of certain hazardous substances in electrical and electronic equipment (2002/95/EC) new programs have to be produced with a lead-free soldering process. Lead-free solder pastes have a higher liquid temperature. Therefore, the process window is smaller for flex base materials.

By using Design of Experiments (DOE) FNM optimized key parameters / profile of the reflow process, i.e. based on design and process verification all solder joints are in line with IPC-A610.

Product & Process innovation Extra large DRL
The design of lighting applications such as day time running lights (DRL) or turn indicators require more and more special formats. As a consequence, standard production panel sizes are no longer feasible or are not efficient for mass production. 
FNM have developed production processes that fit with current customer needs. The company are able to provide extra large SMD assembled DRL up to 900 mm without any foldings. Tolerances 
On the other hand, it is a challenge to produce extra large lighting applications with very tight tolerances, which are necessary due to the optical system (LED, reflector, lens etc). 
FNM are using laser processes for cutting reference holes in the FPC. These reference holes are necessary to realize tight tolerances with next process steps. Depending on the number of reference holes the tolerance of a product with a total length of 500 mm can be adjusted to a tolerance between ± 0.2 mm and ± 0.37 mm (Flex-on-Alu with LEDs).
Besides the tolerance the laser cutting process has two more advantages: 
- The number of reference holes only have a minor impact on process costs 
- A high throughput in serial production is possible with PEN flex material

Production concepts
It is FNM's strategy to optimize the already existing manufacturing processes of lighting products, so that the productivity gets more and more efficient. Moreover, FNM are developing complete new productions concepts to provide mechatronic products that fulfil future requirements.

For low volume production:
For car lines with low volumes it is the aim to reduce tooling costs or even to eliminate tools completely. By using laser punching and laser cutting processes as well as small aluminium stamping tools for LED stiffeners the overall tooling cost can be reduced.

For high volume production:
If a lighting application design (e.g. DRL) is used across several model series and only the total length of the product or the LED technology is altered, the design is subject to a change in status as appropriate.

„From flat wiring to mechatronics."