In an electronic world, where the demand for more rugged connectors is high, overmolded connectors offer a superior connection option.
Overmolding is the process of bringing two separate parts of material together to form one piece. The substrate (the first part of the process) is usually covered by secondary materials. The secondary material is called the overmold material.
In connector basics, the cable assembly is placed inside a mold. Next, a layer of protection is added to the outside of the cable, and then the cable and connector are sealed together to form one, impenetrable piece. There are a variety of different materials used to overmold. This allows for more protection and resistance to specific environmental factors, such as exposure to extreme heat.
What are the benefits of overmolding?
• Reduced costs: Since the end product is one solid piece, it stops the need of secondary assemblies. Which in turn, lowers costs.
• Higher degree of water ingress proofing and shock resistance: The overmold cuts allows for more protection.
• Increased toughness.
• Increased chemical resistance.
• Lightened weight and less bulk: The end product is lighter with the elimination of secondary assemblies.
• Better product insulation.
• Minimization or even elimination of sharp edges: The overmold can create a casing around the whole product, covering sharp edges.
• Almost instantly ready to use: There is no need for extra assembly with overmolding.
• Increased mechanical strength.
• One solid piece.
Harsh weather protection
Without proper safeguards in place, harsh weather, repeated friction, extreme temperatures and exposure to chemicals can significantly reduce the lifespan of your design. Overmolding creates an increased rugged barrier around your electrical connections, protecting the most crucial elements of your design.
For optimized protection, overmolding materials are specific to the application. This prevents corrosion and other physical damages. These materials include:
Plastic substrate, plastic overmold
To start, a plastic substrate is molded to create the first piece. Another rigid plastic is molded around the substrate.
Metal substrate, plastic overmold
The metal substrate will be cast or formed and then plastic is molded around the metal. To put this into perspective, general examples of this include scissors and screwdrivers.
Connector protection in smaller places
When electrical connectors are used in any design, storing and protecting components is imperative. An advantage of using an overmolded connector means that space can be saved. Enclosures can prove to be bulky and require a lot of space but overmolded connectors typically mean that there is a smaller cable assembly, enabling smaller designs. Protection from shock or vibration is also key. Compromise can result in serious failure. That is, unless proper measures are taken during the design phase. When a critical electrical connection is overmolded, plastic resin fills spaces around the internal components. With no space or air gaps, the components cannot shift or move.
Applications
Overmolded rugged connectors are ideal for extreme weather. This also means they are perfect in wash downs, constant sanitation, and frequent strain applications, underwater and above water. Consumer electronics, medical equipment, construction, and industrial applications are all popular applications.
400 Series Bucaneer
Bulgin offers a wide range of overmolded connectors including the 400 Series Buccaneer.
The 400 Series Buccaneer is ideal for designs requiring a small footprint and is one of the most compact connectors within the Buccaneer range. Taking a selection of great features and specifications from the larger Buccaneer family, the 400 Series offers miniature power and data connectors that are condensed into a compact form factor for greater flexibility.
With a lightweight, rugged construction, these easily installable connectors are IP68 and IP69K rated. These sealed circular plastic connectors also offer highly reliable power connections for use within medical, industrial, infrastructure and automotive applications where space is limited. Scoop proof contacts designed into the connector assist when blind mating, preventing damage to pins and connectors.
Condensing the same robust features of Bulgin's larger Buccaneer range into a compact form factor, the 400 Series gives engineers greater flexibility for designs and applications requiring a small footprint. Taking into consideration the connector size, the 400 Series’ capacity of cable diameter ranging from 3mm - 7mm is extremely impressive.
Other overmolded connectors from Bulgin include the Mini USB & SMB, Standard Buccaneer, 6000 Series and Ethernet (Plastic).