Rugged Interconnects for Harsh Environments eBook

• Subminiature cable assemblies D-subminiature and a full range of cable- and PCB-mount sub-miniature connectors and adapters for wireless applications including antennas, telecommunication systems, and networking equipment • RF/coaxial telecommunications cable assemblies

Overmolding encapsulates wire and connector to create a single part.


Overmolding is applicable to any discrete interconnect or component housing a single or multiple interconnects. It is generally specified to encapsulate essential components and assemblies employed in a broad spectrum of commercial, industrial, military, rail, mass transit, shipboard, or agricultural applications in which harsh environments, chemicals, constant sanitation, frequent flex strain, or repeated mating/unmating cycles are factors. Applications where overmolding is most frequently employed include: • Power cable assemblies Intermediate and light-duty assemblies for military, aerospace, industrial, agriculture, and medical equipment • Military tactical communications cable assemblies • Wire harnesses Military, commercial, and industrial

Mission-critical military applications commonly specify overmolded interconnects.

OVERMOLDING IS A HIGHLY ENGINEERED PROCESS The multi-step overmolding process initiates with the selection of overmold plastic material appropriate for the application, i.e., adhesion properties, chemical resistance, flexibility, and color. Commonly specified materials include ABS (acrylonitrile butadiene styrene), PP (polypropylene), PE (polyethylene), LPC (liquid crystal polymer), TPU (soft thermoplastic polyurethanes), TPE (thermoplastic elastomer), and Santoprene TPV (thermoplastic vulcanizates). Low smoke/zero-halogen overmold materials are required for transit, shipboard, and wherever protection from toxic and corrosive gas might be emitted during combustion.


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