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.
CONTROL 2
WT 1-LEVEL Wechseltisch
Materialdruckbehälter
Dosiermaschinenschrank
Mixing head 825 PRO
Control cabinet
Supply Tap
Elevator
CONTROL 2
Optionally available: CONTROL touchscreen operating panel (21.5“) for operating the dosing system
More information to our operating panelsWT 1-LEVEL Wechseltisch
Two pick-up plates operating in pendulum mode in one plane
More information to our shuttle tablesMaterialdruckbehälter
Material pressure tanks (24 l or 44 l, single-walled or double-walled) with minimum level sensors, on a grating platform with adjustable leveling feet and drip tray
More information to our material Pressure TanksDosiermaschinenschrank
The dosing machine cabinet contains the components of the dosing periphery, e.g. the dosing pumps.
More information to our dosing machine cabinetsMixing head 825 PRO
MK 800 PRO precision mixing head with high-pressure water rinsing or alternative component rinsing system
More information to our mixing headsControl cabinet
The control electronics, safety engineering and industrial PC are installed in the control cabinet.
More information to our control cabinetsSupply Tap
Optional: Automatic SUPPLY TAP drum refilling station for low-viscosity products, e.g. isocyanate (B-component)
More information to our refilling stationsElevator
Optional: Automatic ELEVATOR drum refilling station for the A-component with pneumatic lift and agitator
More information to our refilling stations