Overmolded D38999 Circular Connector

Yamaichi's improvement is in the insertion molding of the housing parts. This more than corrects a weak point of the conventional D38999. The weakness of other providers is the processing of the housing. Until now, so-called shrink-formed parts were fitted to a given plug connector under enormous heat in a very costly and difficult shrinking process. In addition to the processing effort and associated cost of manufacturer, the purchase prices of shrink-formed parts are also very high.



Insertion moulding of the housing parts isn't an entirely new approach. However, earlier attempts by other providers have failed, generally due to the technical implementation. The particular difficulty is the physical adhesion. No permanently solid connection could be formed between the molded material and the metallic surface of the plug connector and the cable sheath. The insertion molding of the housing thus separated even after slight mechanical stress.



Yamaichi, thanks to many years of experience with cable assemblies and insertion molding technology, including with photovoltaics, managed to succeed in creating a permanent connection at the molecular level between the individual components of the plug connector, injection molded material and cable sheathing. In addition to enormous mechanical resilience, this also means a high level of protection from moisture, up to IP67.



There are no limits to the choice of shape or colour, and any take-off angle can be fabricated. Different degrees of hardness can also be achieved, from very flexible to extremely stiff and robust, by using custom material mixtures.



The insertion moulding process is far more reproducible and reliable than the processing of shrink-formed parts with heat application. The result is also significantly more aesthetic in comparison. Despite professional processing, there are always slight visual differences after the shrinking process. Insertion molding is also much gentler for the cable and the plug connector.



Customer-specific solutions can frequently amortise from lot sizes of about 300 units, depending on the price of the comparable shrink-formed parts. For standard variants which Yamaichi already tooled up, the break-even can be significantly lower. Yamaichi is happy to consult with its customers on an individual basis.