Overmolding Circular Connectors In Cable Assemblies

What we cover in this blog?

• What Is Overmolding?
• Different Types of Cable Overmolding
• Molded Connectors
• How Do You Overmold a Connector?
• Benefits of Overmolding Circular Connectors in Cable Assemblies

What Is Overmolding?

Overmolding is encapsulating or covering a component, such as a connector or cable assembly, with a layer of thermoplastic material like a cable jacket. This layer not only provides protection but also gives enhanced performance and improves the aesthetics of the component. Overmolded cable assembly materials are commonly used in cable assemblies to create a seamless, integrated, and rugged outer layer that offers several advantages:

• Enhanced Durability: The overmolded layer acts as a protective barrier, shielding the cable and connector from physical damage, moisture, and contaminants. This increased durability is especially valuable in industrial environments where cables are subjected to continual flexing and harsh conditions.
• Customization Options: Overmolded cable allows for customization, including incorporating corporate logos, custom colors, and product identification markings. It serves branding purposes and helps with easy identification and differentiation of products.
• Waterproofness: The overmolded cable can resist water, making cable assemblies suitable for outdoor and wet environments. It is particularly important in applications like medical equipment and factory automation, where reliability is paramount.
• Improved Aesthetics: The molding process can enhance the appearance of cable assemblies, making them more aesthetically pleasing. It is particularly valuable in consumer and home electronics, where appearance matters.

Different Types of Cable Overmolding

A molded assembly cable can vary based on factors such as the type of connector, application, and the preferred qualities of the end product. Here are some common types of cable overmolding:

• Strain Relief Overmolding: Overmolding process protects cable assemblies from mechanical stress and bending. This overmolding reinforces the cable near the connector, preventing damage to the wires and ensuring a longer lifespan.
• Water-Resistant Overmolding: In applications where exposure to moisture or liquids is a concern, water-resistant overmolding is employed. This overmolding method creates a barrier that protects the cable and connector from water ingress, enhancing its durability and reliability.
• Custom Overmolding: The Custom overmolded cable process allows for incorporating specific design elements, such as brand symbols, custom colors, and product markings. Overmolded cables cater to aesthetic and branding requirements by providing a sleek and customized appearance.
• Multiple Molds: Overmolded cable assembly may require overmolding in multiple sections or layers to achieve the desired performance characteristics. These molds apply different types of overmolding components in separate stages.
• Hard Tooling vs. Soft Tooling: Hard tooling involves the creation of permanent molds, which are more expensive but suitable for high-volume production. On the other hand, soft tooling utilizes less expensive, temporary molds that are ideal for prototyping and low-volume runs.

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Molded Connectors

Molded connectors are connectors that have undergone the overmolding process. This process transforms a standard connector into a more robust and functional component. Molded connectors offer several benefits:

• Increased Reliability: The overmolded layer provides added protection to the connector, reducing the risk of damage and ensuring reliable electrical connections.
• Environmental Resistance: Molded connectors are better equipped to withstand harsh environmental conditions, including exposure to moisture, dust, and chemicals.
• Streamlined Design: Overmolding capabilities allow for integrating stress relief and other features directly into the connector, eliminating the need for additional components.
• Budget-friendly: While overmolding adds value to connectors, it is economical for enhancing connector performance and longevity.

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How Do You Overmold a Connector?

Overmolding is a specialized manufacturing process involving injection molding a thermoplastic polymer around a connector or cable assembly. The process typically includes the following steps:

• Mold Preparation: The overmolding process makes a mold in a heated barrel. This mold, also referred to as a cavity, is crafted to perfectly suit the unique shape and size of the molded cable assembly and connector.
• Insertion: The cable assembly and circular connector are carefully inserted into the mold cavity. Ensuring the components are properly positioned to achieve the desired functionality and aesthetics is essential.
• Injection Molded: Once the cable assembly and connector are in place, the mold is closed, and thermoplastic material, often polyvinyl chloride (PVC), thermoplastic polyurethane (TPU), or thermoplastic elastomer (TPE), is injected into the mold under high pressure. The molten resin fills the mold and encapsulates the connector and cable.
• Cooling Process: After the injection of the molten plastic, the mold is allowed to cool. This process solidifies the plastic, creating a protective, functional, overmolded assembly layer around the connector and cable.
• Ejection: Once the plastic has fully cooled and hardened, the mold is opened, and the overmolded cable assembly is ejected. The excess material, also known as flash, is typically trimmed or removed at this stage.
• Quality Control: The finished product undergoes quality control checks to meet the required specifications. It includes verifying the integrity of the overmolded layer, the electrical connections, and overall functionality.

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Benefits of Overmolding Circular Connectors in Cable Assemblies

It provides a myriad of advantages, positioning it as the optimal choice for diverse industries and applications:

• Enhanced Durability: Overmolding materials increases their durability and resistance to mechanical stress, environmental factors, and moisture. This enhanced efficiency is crucial in manufacturing automation, medical devices, and other critical applications.
• Improved Seal: Overmolded cables create a robust seal, safeguarding against moisture, dust, and contaminants.
• Strain Relief: Overmolding offers stress relief, preventing cable damage from bending or pulling.
• Vibration Resistance: It reduces vibration-induced stress, enhancing long-term reliability.
• Cost-Effective Solution: Overmolding offers a cost-effective way to improve cable assembly durability and performance without requiring extensive redesign or additional components.
• Aesthetics: Overmolding can enhance the visual appeal of cable assemblies, making them more attractive and suitable for consumer electronics and other applications where aesthetics matter.
• Longevity: Overmolded cable assemblies tend to have a longer lifespan, reducing downtime.

Conclusion

It is a versatile and effective manufacturing process that enhances the performance, durability, and aesthetics of wire assemblies. With its extensive array of customization options and the capacity to fulfill precise industry demands, overmolding has emerged as the perfect choice for applications in medical equipment, manufacturing automation, home electronics, and beyond. Overmolding will likely play an increasingly crucial role as technology advances in creating reliable and visually appealing cable assemblies for various industrial applications. Whether you are looking for improved performance, customization, or resistance, overmolding offers a solution that meets your needs while ensuring the longevity and reliability of your cable assemblies.