Custom Connector Design

Problem:

Customer needed a connector to withstand 500 lbs of straight pull force, while incorporating a 30 awg coax wire

Solution:

iCONN designed and developed a solution that included:

• Custom Geometry for coax, signal and power
• Self-cleaning threads for an extremely dirty (sewer) application
• Custom cable construction with strength members
• Specific resins for mechanical bonding and sealing

Problem:

Customer needed a product to survive in burning buildings - people's lives at stake.

Solution:

iCONN developed a repeatable process to build robust assemblies with zero defects in application.

Problem:

In application, the Customer's solution was not aesthetically pleasing or robust.

Solution:

iCONN developed a robust assembly method using a custom overmold on titanium housings. Marketing had a visually appealing product for an easier sell.

Problem:

Customer was experiencing field-failures due to a previous custom design.  The current supplier did not factor in the application environment.

Solution:

iCONN designed and printed prototypes for field testing to win the business and prove that our design would survive.

Problem:

The customer needed a low profile battery housing that would allow the end-user to replace batteries, remain sealed and meet industry regulations.

Solution:

iCONN designed and developed a battery housing to fit within the given real estate, and used a custom overmolding process to ensure everything is water-tight.

Problem:

The customer needed a sensitive PCB sealed in a cable assembly - and needed it in 3 weeks!

Solution:

iCONN's low pressure overmolding capability and quick-turn tooling program delivered product to the customer cost-effectively and on-time.

Problem:

Customer needed a PC Board mounted connector that would also seal when installed into their product housing.

Solution:

iCONN designed a connector that could be wave soldered to a PC board and create a watertight seal when installed into the housing.

Problem:

Customer needed a low-profile connector capable of handling 16 positions and a standard off-the-shelf item was not available.

Solution:

iCONN designed and tooled a connector to minimize overall height of product while maintaining an IP67 rating.

Problem:

Customer wanted a connectorized end cap for a light bar that meshed with the size and geometry of their light bars.

Solution:

iCONN designed an end cap overmold with an integrated connector.  This end cap sealed the entire light bar from outdoor elements.

Problem:

Customer needed a cheap, high-volume connector to carry power from unit to unit in series.

Solution:

iCONN designed cheap, yet robust contacts for this connector, and automated assembly equipment to meet high volume demand.

Problem:

Customer needed a connector that mounted to a PC board and would have many sensor replacements.

Solution:

iCONN designed a quick-connect / disconnect solution that would simplify sensor changes for the end-user.

Problem:

Customer needed a low-profile connector capable of handling 16 positions and nothing off-the-shelf would work.

Solution:

iCONN designed and tooled a connector to minimize overall height of product while maintaining an IP67 rating.