Rugged Interconnects for Harsh Environments eBook

OVERMOLDING DEFINED Interconnect overmolding is an injection molding process where two or more materials are used to encapsulate and contain the wire and connector to create a single part. Overmolding provides a solid, seamless, aesthetically appealing seal between connector and cable to deliver optimal protection against liquids, dust, and heat. It also offers strain- relief to enhance protection throughout multiple mating/unmating cycles. Plastic overmolding is available in a variety of colors, materials, and properties to meet a broad range of applications. Custom overmolded interconnects eliminate the need for secondary operations such as sonic welding, bonding, gasketing, plus any ancillary assembly processes. There are three types of overmolding methods frequently specified: • Two-shot sequentia l: The molding machine injects the first material into a closed cavity, then moves the mold to form a second cavity. The first component then is inserted into the second cavity for the second injection, using a second material. • Multi-shot : Multiple injections of multiple materials are injected into the same cavity throughout the same molding process. • Insert : A pre-molded insert is positioned within the mold prior to injecting the second material.

Overmolding encapsulates terminated interconnects to provide strain-relief throughout multiple mating/unmating cycles.

INJECTION OVERMOLDING OPTIMIZES INTERCONNECT LIFESPAN AND RELIABILITY Injection overmolding is exclusively developed to expand the useful life and enhance the reliability of electronic assemblies in the harshest environments. Benefits of injection overmolding include: • 360° strain relief • Increased pull strength • Abrasion, shock, and impact resistance • Water-resistant/water-tight and dust-resistant to meet IP certifications • Tamperproof components • Enhanced aesthetics • Simplified installation to minimize human error




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