Page 35 - 2021 Connectivity Components: Everything but the Connectors eBook

in line in continuous or semi-automatic mode, are among the custom-designed solutions that connector and cable manufacturers who have integrated this expertise are able to offer.
The expertise of various technologies such as cable extrusion, injection of classic or technical thermoplastics (e.g., PEEK, PA, PBT, PPO, PEI, PFA, and ETFE), molding of mono- or bi-component resins (e.g., PUR, silicone, epoxy, and UV), as well as the transformation of elastomers (e.g., silicone VMQ, CR, NBR, PU, FFKM, FVMQ, and EPDM) is a real asset for meeting customer requirements. For example, resistance to temperatures ranging from -80° C to +250° C, or limiting the flame propagation can be required. The applications are diverse, including automotive, defense, space, oil research, and implantable medical fields.
» In this example of a complex interconnect without connectors, the sealed blue overmolding is chemically compatible with the black part visible above. The latter integrates contacts to secure the electrical connection, thus guaranteeing the protection of the custom-made connectors. Continuous overmolding over the extruded cable made by Axon’ Cable takes the form of elastomeric black sleeves that are designed to stay flexible even at -80° C.
An easier integration of links into the customer’s system
The integration of cables and harnesses should be considered early in the design process; however, it commonly is not. The installation of the links must account for their passage through contending structures, including changes in angular direction, and can, therefore, be very complex.
A co-engineering phase is essential to propose the most suitable and ready-to-use solution. The choice of overmolding materials must meet the requirements of the specifications, such as flexibility to facilitate the integration of complex shapes or, alternatively, hardness to resist friction. Abrasion, thermal or chemical resistance, and waterproofing can also be considered.
In addition to providing mechanical protection to the connection, overmolding allows for easier integration into the system. An overmolding achieved with the so-called low-pressure technologies — mono- or bi-component resins or high pressure with thermoplastic materials — gives the product its final shape. This overmolding allows control of dimensions in a very precise and repeatable way. If necessary, the overmold expert will evaluate the necessity of positioning and holding the wire harness in the center of the overmold to avoid injury during installation. Another straightforward option is to integrate plastic or metallic inserts into the overmold (additional functions or a cable- connector link) to strengthen fixings and feedthroughs to seal certain areas.
Fool-proofing parts can also be overmolded and color-coded via the addition of a dye in the material to differentiate several references and to facilitate their integration into the customer system.
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