A dangerous electrical problem was plaguing a large manufacturer of outdoor cooling systems. Their power cords kept shorting out when the systems were installed in wet environments. There were two causes for the shorts: moisture seeping into the connector plug at the coolant circulating pump, and coolant wicking up the power cord to the power supply panel. The shorts created serious safety hazards and caused costly downtime.

We were able to solve both problems by reengineering one of our existing tools to serve as an overmold and applying it onto the cord connector itself. We completely eliminated electrical shorts at the connector and made it impossible for coolant to wick through the power cord. We also added a strain relief configuration to the back of the plug to relieve any bending stress on the internal conductors.

C&M not only solved this customer’s initial electrical integrity problems, we also prevented future wear problems — all at minimal cost. In fact, they were so pleased with the results that they have since turned to us to solve several other knotty cable assembly problems