Dongle Cables, Smart Cables

Overmolded Electronics, Smart Cables, Overmolding Embedded Electronics

Over molding  embedded electronics is an expanding area in the custom cable assembly industry. As I/O connections in electronic devices become more compact, embedding electronic circuitry within the cable assembly becomes a cost-effective alternative to on-board electronics. These cable assemblies are typically referred to as smart cables, dongle cables, or dongles. We offer dongle cables as well as the widest variety of conventional custom cables.

PCBA Overmolding

With an over molded design, the cable can be soldered directly to the PCBA, thereby eliminating both the material cost for the connector and labour for termination. In addition, for almost the same labour required for moulding a strain relief on the cable, the entire PCBA can be overmolded. This combined with significantly reduced tooling cost and more rapid product introduction  OEMs to lower the costs and reduce custom cable production time.

We provide Smart "Intelligent" Cable Assemblies with the following Capabilities:

 Intelligent Protocol Conversion
 Universal Serial Bus (USB)
 Firewire
 Modem Interface Assembly
 Molded PCB Assembly  Configurations
 Ultrasonic Welded Clamshell Products
 Metal or Plastic Backshell Options
 Cable Assemblies with PCB Assembly
 Minimum Length Adapters
 Custom PCB Cable Design
 Custom Power

Advantages of Overmolded Electronic Inserts

In general, Overmolding of a PCBA device is a practical approach when the size of the PCBA is no larger than 10cm X 10cmX 2.5cm and it has a cable attached.

At this point, the real advantages of an overmolded design come into play:

 Reduced cost and lead time for tooling
 Elimination of connector for cable attachment to PCBA
 Improved strain relief for cable exit
 Durability and mechanical resistance to shock and vibration
 Environmental sealing of circuitry
 Security of internal devices
 Cosmetic and functional alternatives

The Injection Moulding PVC Compound used has a moulding temperature between 160 to 180 Deg C and the typical moulding pressure is approximately 30pa.

Direct Electronic Insert Overmolding

Conventional wisdom would seem to indicate that inserting an electronic device into a 30 ton molding press and injecting hot thermoplastic materials at 350°F and 400 psi would not be a wise choice.

However, depending on the PCBA layout and component structure, developing a design with an internal clamshell can eliminate many of the obstacles associated with direct overmolding. This configuration can protect the PCBA and provide a consistent substrate for molding (see Figures 5 and 6).The cost of the discreet clamshell is relatively low, as it is an internal part and can often be soft-tooled.

While not a candidate for all applications, and not a good choice with all suppliers, the right combination can make direct PCB overmolding an unbeatable solution.

For Dongle Cables and Overmolded Electronics at their Best