Customized potting solution for EV charging connectors

 

We carry out developments individually for your specific requirements

The reference material FERMADUR-A-690-UL1 and B-N (B component) is used to seal the cable strands in the EV charging connector housing to make them watertight. This 2- component polyurethane compound cures at room temperature and is temperature resistant from -40 to +80 °C.

It is mechanically particularly stable and tear-resistant as well as low-shrinkage and low-stress. This increases dielectric strength and protection against moisture and corrosion. As a rule, polyurethane potting compounds have good adhesion to plastic surfaces.

As an alternative to the reference material presented, we can also adapt our potting systems to your component requirement and specification.

 

Customized potting systems for maximum product safety

 

The FERMADUR polyurethane compound is applied bubble-free into the receptacles of the cable strands in the charging connector housing using the FIP (Formed-In-Place) technology of our DM 502 mixing and dosing machine via the CNC-controlled MK 825 PRO precision mixing head with high dosing and repetition accuracy.

After dosing, a smooth, even finish is formed which does not show any shrinkage. After curing at room temperature, which can be optionally accelerated by an annealing oven, a compact seal of the desired hardness is produced.

Our potting systems and the fully automated application process for potting the cable strands in the EV charging connector housing are optimally matched to each other and adapted to your specific component requirements.

Reference material

    FERMADUR -A-690-UL1  
    FERMADUR-B-N 
Mixing ratio   3 : 1
Pot life time   130 sec.
Tack-free time   4 min.

Viscosity of the A component

  5,000 mPas
Density of the foam   1.55 g/cm³
Hardness (Shore 00)   84
Temperature resistance   from -40 to + 80 °C
Pretreatment   Plasma / Corona / Primer

In addition to the reference products, we develop material systems according to your individual requirements. Influencing factors include pot life until start of foaming, curing time, and the viscosity, hardness and adhesion properties.


DM 502 mixing and dosing system with 6-axis robot and shuttle table for potting EV charging connector housings with polyurethane potting compound

 

 

Flexible and fully automatic – fully in line with your requirements

The reference configuration shown here for potting the cable strands in the EV charging plug housing consists of the DM 502 mixing and dosing system for two material components using a 6-axis robot and the WT 1-LEVEL shuttle table.

A machine operator or, optionally, a Pick & Place robot places the EV charging connector housings and the coiled charging cable on the part holders of the shuttle table plate and inserts the cable strands into the charging plug sockets in preparation for the potting process.

Potting of the cable strands in the receptacles of the housing is performed by the mixing head of the DM 502 in continuous shuttle mode of the two pick-up plates in one plane.

The 6-axis robot ensures repeatable accuracy in guiding the robot arm’s MK 825 PRO precision mixing head over the component. During this process, FERMADUR polyurethane material is fed into the receptacles of the charging plug housing for potting the cable strands in a fully automatic process with high dosing accuracy and dimensional precision.

The dosing nozzle reaches as deep as possible into the component so that it is filled from the bottom to the top without bubbles or air pockets being formed. After curing, a compact seal of the desired hardness is formed and the cable strands are therefore firmly connected to the connector and protected.

Where components are to be applied with a combination of both potting and sealing foam in a single production step, the dosing application can be carried out with the DM 503 mixing and dosing system for 3 material components which is equipped with three pressure vessels to supply the material.

Our fail-safe mixing and dosing systems can be operated easily and intuitively without the need for extensive training.

Thanks to the automatic logging of dosing program data, all process data can be traced and evaluated by the machine operator via the CONTROL 2 operating panel while production is running.

As process experts, we support you with tailored advice for the automation of your manufacturing processes.