"...moulding of wiring harness junctions is bringing added flexibility to designers of wiring systems..."

ServicesMoulding

Phoenix Dynamics' low pressure moulding capabilities allow quick and cost-effective manufacture of moulded components and can also be used to create and protect wiring junction points. These can be further improved by the incorporation of other features, such as clipping or mountings that can help minimise weight, and also reduce costs, due to the elimination of additional components. The relatively low-cost nature of the tooling required to create these joints also allows this moulding technique to be utilised for low volume applications where required. Its flexibility means that bespoke shapes to suit specific routing or installation requirements can be easily manufactured. Molded and over-molded cable assemblies are prime examples of its use.

The system is also component friendly by virtue of a combination of the low pressure used and the low heat requirement when creating the moulding means that it is ideally suited to technical wiring systems as it is non-destructive to electrical components. The material used in the process, a hot melt adhesive, provides an extremely tough mechanical protection but at the same time gives excellent sealing properties. It can, therefore, be used to address the most challenging of environmental conditions in which these wiring harnesses often operate.

The process can act as an alternative to traditional heat shrink boots used to seal the rear of connectors or at wiring harness junction points. However, the major advantage of over-moulding the joints using this method is that it makes it possible to create any size, number or orientation of harness branches, making it ideal for complicated harness layouts and constructions.

The precision moulding of wiring harness junctions is bringing added flexibility to designers of wiring systems as we can now provide them with the potential to design bespoke shapes to allow specific routing or installation to be achieved, while at the same time adding additional ruggedisation to the harness itself. The ability to mould in clipping, or mounting, features should be of interest to designers and buyers alike as it will allow greater design flexibility while reducing unit costs by eliminating the need for additional components.

A further use of the moulding system is the encapsulation of critical electronic components. Items such as PCBs can be fully sealed and protected against the harshest of environments.


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Over-Moulded ConnectorsOver-Moulded Connectors
Bespoke Moulded ShapesBespoke Moulded Shapes
Controlled Cable RoutingControlled Cable Routing
Complex Moulded JunctionsComplex Moulded Junctions
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