Hybrid components for the highest demands

As a rule these components are used to hold electronic assemblies which can be electrically connected via a variety of different contacting possibilities. As well as contacts with a soldered connection, solderless contact elements with press-fit or bonded zones are also used. With regard to connectors all conventional connection techniques are offered.

Other insert components include, for example, machined or stamp-rolled bushings, seals or pressure equalisation elements.

In order to manufacture safety-relevant components in the required quality, a zero-defect culture within the company must be practised. Equally, fully automated production of the components is absolutely essential as every manual task is prone to error.

Fully automatic production of our sensor housings means that in the machine the contact strips are fed into the stamping tool, separated and, if necessary, bent. The remaining inserts are supplied by suitable handling units, inserted in the injection mould and subsequently overmoulded with plastic. In order to reduce the process time we use either a turntable injection moulding machine or a mould carrier transport system. This makes it possible for the mould to spend the majority of the residual cooling time outside the injection unit (moulding machine), thus increasing the capacity of the machine by up to 70%.

This is followed by an integrated inspection for short circuit as well as checking that the workpiece is sealed, dimensionally accurate and co mplete. Ejection of defective parts, marking of good parts and packing are also carried out fully automatically.

A particular challenge in the production of such parts is the required cleanliness in terms of metal contamination, as this constitutes a risk of short circuit within the complex electronic assembly. To achieve this the various production processes such as separating and bending of the metal pins or handling of the bushings must be accurately coordinated. The gripper system must place the inserts into the tool with utmost precision to prevent the production of tinsel. The cleanliness of the starting material is also subject to very high demands.

With its IATF 16949 certification, 2E meets the high quality demands of the automotive industry. Production of the sensor housing is solely in Germany. Our excellent local infrastructure guarantees a reliably high standard of quality, short distances and fast response times. In addition, the fully automatic 2 4/7 production processes facilitate cost-effective manufacturing of the products.

2E’s professional project management guarantees optimum solutions for developing and implementing manufacturing concepts. Many years of experience help to optimise the feasibility of the products and consequently generate a smooth production process. From the first contact through sample product to series production our customers are given optimum support and advice. Any requests for change during the development process are implemented quickly and flexibly.

In addition to hybrid plastic components the range of 2E mechatronic products also includes, among other things, capacitive inclination sensors, MID flow sensors, MID-based LED/OLED lighting elements as well as microliter pumps. Consistently geared towards the specific requirements of our customers our products are used in the automotive industry, medical technology, industrial electronics and automation.

Thro ugh our involvement in numerous research projects, pioneering production technologies and innovative products are continuously emerging. For us sustainable and environmentally-friendly working methods are just as important as social commitment (for example to the Wilhelm-Narr-Foundation). Furthermore, with our flat hierarchy and professional teamwork, we are able to operate quickly and flexibly in the market.

Author: Dr. Andreas Pojtinger, General Manager of 2E mechatronic