Why does the cable harness assembly need to be overformed? What are the benefits of overmolding wiring harness components?

Why does the cable harness assembly need to be overformed? The process of overforming cable harness assemblies involves injecting plastic resin around critical electrical connections under controlled conditions, resulting in a very powerful and durable connector product.

What are the benefits of overmolding wiring harness components? There are four points: intrusion protection, shock and vibration protection, increased resistance and reduced wear, and compact assembly and integration. Below are details of these benefits:

1. Intrusion protection

By controlling the configuration of the materials used and the over-molding process, material bonding can be created around the cable harness and connector. These bonds provide the seal required to achieve watertight joints, which have generally passed the IP67, IP68 and IP69k standard tests.

2. Shock and vibration protection

The overshaping process fills the space around the internal components, leaving no gaps. This situation inherently prevents overformed parts from moving or moving within the assembly, and the structure is well suited to eliminate fatigue and other damage associated with continuous horizontal shock and vibration.

3. Increase resistance and reduce wear

Overformed materials can be selected to provide extreme resistance to physical abuse and vibration. The preferred material for harsh and harsh environments is polyurethane, which is available in a variety of wire harnesses, has high load capacity, and has strong impact and wear resistance, making it ideal for harsh environments at all temperatures.

4. Compact assembly and integration

The use of cladding overforming techniques in the design of cables or electronic components usually results in smaller components than alternative assembly methods such as mechanical rear shells or enclosures. Smaller overall package sizes help to reduce the size of the equipment. The overforming process can also accommodate additional components, such as diodes for reverse polarity protection or resistors for circuit analysis.