Cavist Solves Problems

Here are just a few problem and solution examples of how Cavist has helped solve customer problems with electronics by using design and engineering innovation with with contract manufacturing to encapsulate electronics.

Under-hood Sensors for Automotive Aftermarket

Problem:

A family of automotive sensors for maximizing performance and fuel efficiency of diesel trucks suffered an unacceptable amount of field failures. The original sensors were manufactured by installing two clam shell halves around the circuit-board to protect it against the force of conventional over-molding. The assemblies failed in service because moisture was leaking around the connector edges as well as around the cable because of poor adhesion and seal.

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Solution:

Over-mold circuit-board assemblies directly with Low Pressure Molding without the need for internal clam shells. The adhesive molding compounds fully seal the assembly and the gentle over-mold does not damage the fragile circuitry. An added benefit allowed by eliminating the clam shell was the freedom to create a more efficient design of the over-mold shape. The resulting product incorporates new mounting and interlocking features for this family of modular sensors. Cavist manufactures these sensors turn-key: We procure circuit board assemblies and other components to customer specifications. We solder and assemble the sensor harnesses, over-mold and test, then package them for shipment.  Our manufacturing processes are handled under the guidelines and control of the ISO 9001:2008 system.

Charging Connectors For Electric Utility Vehicles

Problem:

A family of automotive sensors for maximizing performance and fuel efficiency of diesel trucks suffered an unacceptable amount of field failures. The original sensors were manufactured by installing two clam shell halves around the circuit-board to protect it against the force of conventional over-molding. The assemblies failed in service because moisture was leaking around the connector edges as well as around the cable because of poor adhesion and seal.

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Solution:

A simple redesign of the connector face plate to eliminate the compartment and the lid. Custom designed low pressure over-molding of the circuit board including molded strain relief  for four exiting wires. The over-molding seals the assembly to IP67, has eliminated all moisture ingress problems and also protects against vibration and impact. After manufacturing more than 300,000 units, this has proven to be a superior manufacturing solution.

LED Boards For Outdoor Displays

Problem:

Large outdoor LED displays are often used for concerts and sporting events. They are typically epoxy-potted assemblies that form heavy “bricks” which require extensive scaffolding work to install. This presents a problem for many events of shorter duration because the installation cost can be prohibitive for a weekend event.

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Solution:

Design a modular LED system with a very slim low pressure over-mold to fully seal the LEDs. The over-molded LED assemblies weigh less than 20% of their epoxy-potted counterparts because the molding compounds are light and the over-mold is shaped to follow the outline of the LEDs on the board. We have over-molded many millions of LEDs that have been used for hundreds of performances and are still going strong.