Application | Overmolding

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OVERMOLDING FOR ROBUST OUTDOOR POWER CONNECTIONS

For power connections, the great outdoors really isn’t so great. And when it comes to military operations in demanding conditions, reliable equipment performance can become a matter of national importance. ///////////////////////////////////

50’ 4” / -0”

This drop-in replacement reduced material costs substantially while also reducing installation labor compared to the legacy assembly. The overmolded cable assembly also looks more appealing, which doesn’t affect performance but does give the impression of improved quality. Many other types of military equipment make use of overmolded cable assemblies, but there are many applications in the civilian world too. Chemical process, oil-and-gas, alternative energy and industrial equipment can all benefit from overmolding whenever they have to operate in harsh conditions. To learn more about overmolded cable assemblies, contact the ÖLFLEX ® CONNECT team at 1-800-774-3539 or sales@lappusa.com.

The outdoors present a never-ending list of challenges for electrical equipment and components. Constant exposure to moisture, dirt, temperature extremes, high strains and abrasion can shorten the life of unprotected cables and connectors. To protect power connections from harsh outdoor environments, it often pays to combine them into an overmolded assembly. These overmolded assemblies consist of a connector and cable that have been encapsulated by a molded thermoplastic or rubber elastomer. The overmolded elastomer creates a protective shield against the rain, dirt and other contaminants. When properly designed, overmolded assemblies can also help protect against the thermal cycling, abrasion and high strains common in outdoor environments. Overmolding does require more upfront design work and manufacturing know-how than a comparable mechanical assembly. And the results are worth it, especially in mission critical applications. One of LAPP’s military projects, for instance, involved the power generation for remote camp buildings. Based on metal cargo containers, these buildings can be dropped into remote settings by helicopter. Once delivered and set up, they have to be self-contained and reliable. Initially, the connection to the buildings’ power generation systems relied on mechanical cable assemblies that incorporated a 60-amp Mil- Spec connector. That assembly, however, had no real protection from the elements. So LAPP’s ÖLFLEX ® CONNECT team designed and delivered an overmolded version that works as a drop-in replacement for the legacy assembly.

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LAPP 29 Hanover Road, Florham Park, NJ 07932 T. 800 774 3539