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===10.1 Hybrid Frames and Housings===
Hybrid frames and housings serve as the connecting points between mechanics and electronics ''(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.
Fig. 10.1: Component with hybrid housing for use in automobiles
===10.2 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 ''(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 to reduce manufacturing tolerances to levels below those achievable with conventional assembly methods.
Fig. 10.2: Examples of strip over-molded contact components
Fig. 10.3: Examples of assembled contact components
===10.3 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 ''(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.