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Connector Insights from iCONN

Flex/Bend Strain Relief Endurance Testing

Posted by Rick Regole on Mon, August 2, 2021

Cable and connector assemblies typically go through testing, also known as “qualification” or “verification and validation,” to ensure that the product design meets the demands of the intended application.

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Temperature Rise Testing for Cable Connectors

Posted by Rick Regole on Mon, July 12, 2021

Customers continue to raise the bar for cable assembly manufacturers who must continuously innovate new products to meet increasingly demanding applications. For example, in automotive applications, wiring in the engine compartment can easily reach temperatures over 195 degrees. When it comes to high-temperature applications, all cable and connector components must be carefully evaluated via temperature rise testing.

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UV Resistant Overmold Materials

Posted by Rick Regole on Mon, June 28, 2021

UV radiation is a silent and invisible enemy to outdoor electrical applications and represents one of the primary causes of plastic deterioration in outdoor equipment. When a cable’s protective outer jacket is exposed frequently, consistently, and for long durations to ultraviolet light, radiation changes the molecular structure of elastomers in the plastic overmolding material, causing them to crack and break down. Eventually, damages can expose delicate internal electrical components, causing safety hazards, dependability issues and cable failure.

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Industry 4.0 Explained: What It Is and How It Works

Posted by Rick Regole on Mon, June 14, 2021

Since the dawn of time, humans have transformed the resources around us into powerful new tools that reshape the world. Industry 4.0 is the fourth industrial revolution that represents how the Internet of Things (IoT) will change everything about the way we manufacture, work, communicate and interact with machines and the world around us. But before going into granular detail about what Industry 4.0 means for the future, let’s revisit the three revolutions that came before. Without them, Industry 4.0 wouldn’t exist.

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Low-Pressure vs. High-Pressure Overmolding

Posted by Rick Regole on Mon, May 24, 2021

Manufacturers use a few different techniques to overmold, seal and protect cables and electrical connectors from moisture, dust, debris, vibration and strain. The two most popular overmolding techniques are “low-pressure” and “high-pressure.” Each technique has its pros and cons, but ultimately, the method a manufacturer chooses to use for overmolding depends on the type of electrical assembly and application.

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Common Wiring Harness Problems and What You Can Do

Posted by Rick Regole on Mon, May 10, 2021

A wiring harness is a tightly configured bundle made up of individual wires — each with its own protective outer-jacket. This bundle can be dropped into an electrical system to significantly simplify and expedite the installation process instead of placing each wire one at a time. Due to their compact formation, wiring harnesses reduce movement and abrasion, prevent short-outs, and can extend the lifespan of an electrical assembly compared to an assembly of individual wires. However, despite numerous benefits, wiring harness problems can arise.

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The Difference Between a Wire Harness & Cable Assembly

Posted by Rick Regole on Mon, April 26, 2021

Wire harness, cable assembly, cable harness, wiring assembly...these words get used interchangeably, but are they the same thing? The technical answer is no. Wires and cables perform a similar function in different ways. Likewise, so do assemblies and harnesses. For this reason, terms like wire harness, cable harness, and cable assembly must not be used to describe the same solution. Here’s what product teams and engineers should know about the key differences.

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When to Use a Mating Cable

Posted by Rick Regole on Mon, April 12, 2021

There’s more than one way to effectively complete an electrical circuit. Many major appliances are designed for hardwiring, which permanently affixes cables from point-to-point into a system. Others prefer the plug-and-play flexibility of a mating cable. Both approaches have their advantages, but when it comes to practicality and economics, a mating cable often makes the most sense.  Here’s our advice on when to use a mating cable over other installation methods.

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How Underwater Connector Manufacturers Provide High-Performance Solutions

Posted by Rick Regole on Mon, March 29, 2021

The underwater connector market is projected to hit $2 billion by 2026. Market growth is primarily attributed to increasing fossil fuel demands, deep-sea explorations, and higher budgeting for naval fleet expansion, among other factors. For underwater connector manufacturers, rapid market expansion means increasingly-fierce competition, especially for long-term contracts—the proverbial white whales of the electrical manufacturing marketplace. To win those contracts, manufacturers must continuously innovate, not only the solutions they create, but also the processes they employ to take solutions to market.

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4 Mating Connector Issues

Posted by Rick Regole on Mon, March 15, 2021

Electrical mating connectors consist of two pairing halves — a male end and a female end. As the joint responsible for transferring the flow of energy, achieving a secure and reliable connection between these two halves is mission-critical. However, the cross-section between any two components also represents a point of vulnerability. Here are the most common issues you’ll find with mating connectors.

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