Why You Should Use Over-Molded Cable Assemblies?

 

Over the decades, over-molding has dramatically changed the appearance and functionality of electrical assemblies. Over-molding is a controlled process that involves injecting a plastic resin into a mold to enclose critical electrical connections. This process improves their overall longevity as well as reliability.

Key Benefits of Over-Molding in Electrical Assemblies

Over-molding not only benefits electrical industries but this method is also employed for a wide ranges of functions in many industries including medical devices, agricultural, consumer and automotive products as well as components. The result of this method is a highly robust and durable product with the following key attributes:

1. Increase Protection: In the over-molding process, the materials used and mold configurations are highly controlled. This can form a bond around connectors and cables. These material bonds result in the watertight seal around critical cable assemblies. If you are looking to extend the protection level of electrical components, this process will help you to achieve IP67, IP68 and IP69K standards. More to this, properly molded connectors can easily pass stringent industry standards.


2. Protection from Shock and Vibration: If your product is subjected to high vibration or shock environment, it increases the risk of mechanical failure or damage. So, it is crucial to take preventive measures were during the design phase. Over-molding process fills the gap around the internal components. This prevents over-molded electrical components from moving within the assembly.


3. Shield from Physical AbuseHarsh weather, extreme temperatures, and repeated friction significantly reduces the lifespan of the product. Over molding forms an ultra-rugged barrier around electrical components to prevent them from various types of physical damage. The material used to over-mold electrical connections is polyurethane. Polyurethane has a high load capacity and is available in a variety of harnesses. It is used in various applications where human handling is critical.


4. High Compressed Assembly and Integration: Over-molding process usually produces a smaller assembly than alternative assembly methods such as mechanical back-shells. This small size enables equipment designers to minimize the size of their component or equipment. Additionally, this process protects components such as resistors, PC board assemblies, electrical switches, and diodes, resulting in an improved performance.


5. Flex and Strain Relief: This is one of the key design features that integrate a cable to the connector which offers protection from damage. Improper handling of the cable results in the failure of electrical components. The lifespan of an over-molded assembly is improved by different types of relief geometries, which mainly include straight, split 45-degree, and 90-degree.

A low-pressure over-molding process allows to over-mold assemblies without harming components. High-pressure over-molding offers a wide choice of materials based on the application environment. Veejay Plastic offers brilliant over-molding services no matter what the requirement. The company offers custom solutions for high as well as low volume requirements.