Title
Integrated Solid State Switch
MCM Technology achieves a size reduction of 40%
Technologies used

MCM

Industrial sector (PRODCOM code)
    34-35 Vehicles & Automotive Parts
Abstract
I.G. Bauerhin GmbH is a medium sized company with 450 employees specialised in the design and manufacture of electronic equipment for automotive industries. The product range covers wire harnesses, seat heaters, electronic control units for automotive production as well as other consumer products.

Core skills are design, manufacturing and system integration of seat heaters and control units for the automotive industries. The items of the product range comprise conventional through-hole PCBs and SMD technologies

The objective of the experiment was to realise an integrated solid state switch with MCM-technology to enable the company to extend their market shares in the field of low-cost controlled seat heating units for motor cars. In most cars, the module is located under the seat. Functional objective was the design of a unit appropriate for build-in in the central electronics or in the proximity of the switch on a plug-in place. Additionally, the MCM-C technology offers more possibilities to integrate such components in the heating element, in the wire harness. For use in heated steering wheels they can be located under the air bag. This allows the company to introduce their new product within new car series where an integration of the seat heating within the seat is required. The company will offer this product with a reasonable price to new customers and so increase their competitiveness in this difficult market segment.

The component is a miniature solid state switch applied for a heating module with temperature and operating check-up based on PCB technology. The module is used in cars for seat heating. On the PCB the following subsystems are realised processor or analogue controller, over voltage protection, EMI protection, input and output drivers and high current switches. These functionality is based on standard components and operational amplifiers.

The current system is too large for integration in a wire harness or into the sink itself (seat heater). This application experiment will enhance the products performance by integrating the MCM technology into the product so as to:
- Reduce the size and weight of the product
- Reduce the failure rate during the live time and to increase the reliability
- Reduce the Electromagnetic interference problems (smaller size)
- Improve temperature performance of the system

The reduced size of a MCM system offers the usage of the system in applications, which are not to be realised with PCB technology, e. g. in the steering column gear change.

The company has gained the following experience through the first use of MCM technology:
- MCM design skill acquisition
- Planning and realisation of design and production of MCM technologies for electronic systems together with external partners
- The impact of software configuration control mechanisms on the quality system, design and manufacturing control in a small company
- Best practice for MCM and final product testing techniques
- Economic benefits of MCM solutions including product price effects, manufacturing costs and the impact on the company's turnover
- Product compliance with applicable legal regulations and standards

The AE duration was 13 months and (including a 3 months break) and required an investment of 97200€.

A payback period of about 15 month will be realised because of the multiple use of the component and the resulting high number of pieces.

Estimating a 5 years lifetime of the product and an increase of profit of 20% from the additional turnover an ROI of about 971% is estimated.
Company
I.G. Bauerhin GmbH
Philipp-Reis-Straße 28
D-63584 Gründau
Detailed information
You can also benefit from microelectronics

MCM technology provided I.G. Bauerhin GmbH with the means of improving its products and enhancing its market position. You can also achieve significant benefits by acquiring the right microelectronics technology and utilising it in your product or manufacturing process. You can get help from FUSE to realise this.

FUSE is a technology transfer programme, funded by the European Commission to stimulate the wider use of microelectronics technologies by European enterprises to increase their competitiveness and enhance their economic growth. The demonstrator described here is one of many examples in the public FUSE portfolio covering the whole spectrum of microelectronics technologies and spanning a wide range of applications and industry sectors.

FUSE provides you with:

  • Best practice in acquiring specific microelectronics technologies and conducting full development projects through the FUSE portfolio of real life demonstrator documents.
  • Local training and expert support to plan your innovation realistically and help you conduct your project successfully.

Further information and support relating to this and other demonstrators can be obtained from the addresses below.
Further information   Guiding Technology Transfer Node
For further information and support regarding this case study, please contact a Technology Transfer Node (TTN) in your region.
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