VanderLaan, prior to joining Visteon, had been in the connector business, so he has familiarity with what he says is an item that has lots of warranty issues associated with it. A problem, VanderLaan explains, is that when terminals are plugged into connectors in the assembly plant, it is difficult for the assembler to be certain that a complete connection has been made. Using soldered bonding of flat wire strips can eliminate that concern. But VanderLaan admits that automotive assembly plants are set up to handle wiring harnesses and connectors, not to perform operations that are typical of, say, a Panasonic plant. There is an infrastructure in place to make them and to handle them in plants.
Flat wire lacks the advantages of the incumbent.
A better-lit interior provides better utility for the consumer and a safer driving environment. But if you look at the average sedan, even the basic controls like the fuel door latch and seat adjustments lie deep within the shadows of the dome light. Even on vehicles that have extra overhead lights or brighter bulbs, illumination far from ideal. Traditionally, the need to light the interior of the car has been something of an exercise in minimalism for a variety of design and production reasons. Wiring harnesses, sockets and bulbs all add cost and weight to the vehicle, take up increasingly valuable space behind interior panels and headliners, as well as create additional assembly nightmares.