Integral Molding
Flat ribbon cable conductors are IDC mass terminated to preformed contacts
and the entire terminated cable end is enclosed in a mold configured as a
connector. Hot, molten polyester thermoplastic is then injected into the
connector mold under intense pressure. The pressurized molten plastic penetrates
and fills all mold cavity space while simultaneously engulfing the shouldered
portion of the contacts, the cable cut off end, and the insulated lead-in
portion of the cable itself. (See picture below) The PVC insulation is thermally
fused to the polyester plastic of the connector body.
The finished part, now an integral, single-end assembly, cools and is ejected
from the mold. For double-ended assemblies, the opposite cable end also is IDC
mass terminated to contacts and molded into a connector body.
One-piece daisy chain assemblies are produced by using through-cable molds that
permit any connector body style, except SRB's, to be molded around IDC mass
terminated contacts anywhere on the cable.
Special configuration, one-piece assemblies incorporating any number of
connectors, with the same or different body styles and sizes, are easily
produced to customer specifications with our unique "molded-on" process.
All cable is industry standard 0,050 in. (1,27mm) pitch round conductor flat
ribbon cable including single-row assemblies.
Structural and Electrical Advantages
A polyester thermoplastic was selected for the connector body material
because of inherent mechanical strength, dielectric strength, flame retardants
and moldability properties.
The advantages for one-piece cable assemblies (listed in the picture below) are
numerous and distinctive. These benefits derive exclusively from the "molded-on"
concept, and are unachievable with other manufacturers' cable assemblies
consisting of many separate plastic and metal parts that rely on mechanical
means of attachment to the cable.
Unlike multi-piece mechanical assemblies, A P Products' one-piece cable
assemblies have no air space between adjacent IDC contacts. The contacts and
cable are embedded in a solid block of plastic, providing significantly improved
insulation resistance and higher breakdown voltage.
Because the body plastic encases the shouldered portion of the contact shank as
well as the cable, it functions as a unifying medium that anchors both against
relative motion. This important advantage is markedly absent in assembled
connectors where the contacts are only loosely retained by mechanical means.
Another unique advantage of "molded-on" cable assemblies is that they need no
added-on strain relief as do mechanically joined assemblies. Thermal fusing of
the cable to the connector plastic creates the ultimate strain relief that is
unachievable by simply clamping. The "molded-on" strain relief also permits a
low profile since bulky wrap-around covers are unnecessary.
