Overmolding for Enhanced Durability

Overmolding refers to the covering of electronic components. Specifically, components prone to wear and exposure to external influences are often overmolded. This enhances the durability of electronic components. CiS applies the overmolding process at the junction between the cable and connector. This protects the connection point from mechanical stress and provides a watertight seal.

Various techniques and processes are available for overmolding cables. CiS employs injection molding machines for this process. An insert, such as a plug with a soldered cable, is placed into the lower section of an injection mold. The selected liquid plastic material (such as PVC, PUR, or PA) is then injected into the chamber under high pressure through the molding nozzle, encapsulating the insert in its designated shape.

This injection molding technology is also referred to as hybrid technology, as multiple metal molds can be encapsulated in plastic in a single step. Plastic-coated plugs and cables provide an ideal solution in various electrical engineering applications, offering protection against external environmental factors such as lubricants, gasoline, gases, temperature fluctuations, and mechanical stress. Depending on the application, different overmolding options are available. Some common overmolding applications include:

• Overmolding for strain relief
• Overmolding for handle caps
• Enhancing the sealing of Y-connections
• Manufacturing of anti-buckling sleeves
• Encapsulation of plug connections

Different methods are available for overmolding cable connections. The injection molding process is a specialized form of casting primarily used for processing plastics. The choice of overmolding method depends on the type of components being overmolded (e.g., connectors, cables, electronic components) and the type of plastic used. Depending on the application, either the low-pressure or high-pressure injection molding process may be used.

The low-pressure process is ideal for overmolding sensitive components. The plastic is heated until liquefied and injected into the cavity at high speed, encapsulating the respective inserts. The thermoplastic material solidifies after molding. Once solidified, the component is removed from the mold. Injection molding is particularly suitable for overmoulding inserts made of electromechanical components, cables and metals.

As a type of low-pressure process, the Macromelt method offers an environmentally friendly alternative to the high-pressure process. This is due to its lower injection pressure and shorter cycle times compared to conventional methods.

At CiS, you benefit from cost-effective and eco-friendly technologies, enabled by faster drying times and reduced energy consumption.