The process of overmolding connector and cable harness assemblies involves the injection of plastic resins around critical electrical connections under controlled conditions, and the result is a very strong and durable product. Four benefits of overmolding connector and cable harness assemblies.
1. Intrusion Protection
By controlling the materials used and the configuration of the overmolding process, material bonds can be created around cable harnesses and connector. These bonds provide the seal needed to achieve watertight connectors that have generally been successfully tested to IP67, IP68 and IP69k standards.
2. Shock and vibration protection
The overmolding process fills the space around the internal components, leaving no voids. Inherently, this prevents overmolded parts from moving or shifting within the assembly, and this construction is ideal for eliminating fatigue and other damage associated with continuous levels of shock and vibration.
3. Increase resistance to reduce wear
Overmolded materials can be selected to provide extreme resistance to physical abuse and vibration. The preferred material for use in harsh and hostile environments is polyurethane, which is available in a variety of harnesses with high load capacity and extreme impact and abrasion resistance, making it ideal for use in harsh environments at all temperatures.
4. Compact assembly and integration
The use of overmolding techniques in the design of cables or electronic assemblies often produces smaller assemblies than alternative assembly methods such as mechanical backshells or housings, and the smaller overall package size helps reduce their device size. The overmolding process can also accommodate additional items in the assembly, such as diodes for reverse polarity protection or resistors for circuit analysis.