DP Seals is supplying Hypertac with interfacial seals for its high-density PCB connectors. Ensuring the accuracy and precision demanded by these fluorosilicone seals – used in challenging applications such as aerospace and defence, mass transit and marine – set DP Seals one of its toughest tooling tests.
Hypertac is recognised worldwide as one of the most reliable suppliers of high performance interconnect solutions for the most demanding applications. For the interfacial seals in its latest generation high-density PCB signal connectors, the company turned to DP Seals.
The seal needed to ensure electrical isolation and maintain mating tolerances between the connector pins as well as high reliability protection against fluid ingress.
“We were extremely impressed with DP Seals’ materials knowledge and manufacturing quality, and the pro-active role they took in helping us develop the solution.”
Anthony Hall, lead engineer, Hypertac
Hypertac’s PCB connectors use 0.6mm pins in multiple rows on a 0.953mm staggered pitch, dimensions the tool needed to match accurately whilst adding detail essential in ensuring a tight seal against dirt, oil and other liquids; the seal itself is just 3mm thick.
To meet this demanding requirement, DP Seals fabricated a set of tools where each individual connector pin is represented by a custom-designed 0.7mm minimum diameter tool steel pin, held in place with a M0.6 countersunk screw just 2.5mm long.
“Hypertac gave us one of our most demanding tooling tests for many years. We even had to manufacture our own Philips screwdrivers for the job”
Russell Willis, Tool Room Manager, DP Seals
DP seals now also manufactures very small, 4mm x 2mm, pin isolators that exhibit complex sub-millimetre detailing for Hypertac’s latest military connectors.