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→Assembled Contact Components
For achieving the highest possible functionality of the end product, a close cooperation between the manufacturer and the end user in the early phases of development and design of new custom tailored electromechanical components is recommended. Innovative and cost-efficient designs can be realized through the combination of the know-how of the manufacturer in for example contact, coating, stamping, plastics processing, assembly technologies and the mostly rather complex requirement profile given by the end user. Besides the contact components , the plastic materials are the critical building blocks for electromechanical components. The Plastics used , are mostly technical thermoplastics and heavy-duty plastics which fulfill the requirements for high mechanical strength, temperature stability, and fatigue strength (<xr id="tab:Frequently Used Plastic Materials and their Properties"/><!--(Table 10.1)-->). For the final selection of a plastic material , economical considerations and the avoidance of environmentally hazardous ingredients , such as for example flame retardants , must be considered. The application of the most suitable contact material coating and the selection of carrier materials are covered in chapters [[Contact Carrier Materials|Contact Carrier Materials]], [[Surface Coating Technologies| Surface Coating Technologies]] and [[Applications for Bonding Technologies|Applications for Bonding Technologies]].
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== Hybrid Frames and Housings==
Hybrid frames and housings serve as the connecting points between mechanics and electronics (<xr id="fig:Component with hybrid housing for use in automobiles"/><!--(Fig. 10.1)-->). They allow the transmission of signals or electrical energy. The connection to the current paths inside the housing is mostly done by bonding with aluminum wires. The over-molded lead frames are typically manufactured from aluminum clad strip materials , which are well suited for bonding. The connectors integrated into the housing for transferring the current paths to the outside , are coated with tin, silver, or gold, depending on specific requirements.
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[[File:Component with hybrid housing for use in automobiles.jpg|rightleft|thumb|Figure 1: Component with hybrid housing for use in automobiles]]
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== Continuous Strip Over-Molding==
In strip form , over-molded contact parts reduce the complexity of assembly of the finished product. This complexity constantly increases with adding additional subcomponents (<xr id="fig:Examples of strip over molded contact components"/><!--(Fig. 10.2)-->).
The strip over-molded contact parts can be tested for various quality parameters during manufacturing , to continuously ensure the ever increasing reliability requirements of the end components.
Combining stamping and molding techniques in an automated production line allows the stamped contact parts to be molded into plastics as a complete functional unit. This also allows enables to reduce manufacturing tolerances to levels below those achievable with conventional assembly methods.
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[[File:Examples of strip over molded contact components.jpg|rightleft|thumb|Figure 2:Examples of strip over molded contact components]]
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==Assembled Contact Components==
For applications and materials which do not allow strip over-molding, semi or fully automated assembly processes can be utilized. Different single parts, like printed circuit boards, stamped parts or contact components are assembled together with plastic molded parts on specialized equipment to complete functional components with low tolerances and high levels of functionality (<xr id="fig:Examples of assembled contact components"/><!--(Fig. 10.3)-->). This also allows to integrate components which otherwise are difficult to mount onto circuit boards or carriers, such as capacitors, coils or sensor elements into the functional component assembly. Contact parts used in these components are already tested on the assembly machine for quality parameters and functionality.
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[[File:Examples of assembled contact components.jpg|rightleft|thumb|Figure 3: Examples of assembled contact components]]
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