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Case study · Industrial adapter protection

Potted interface adapter for factory use

An interface-conversion adapter had to survive real factory handling: vibration, occasional drops, humidity, warm enclosure conditions, and contact reliability risk. ContiMech selected the compound, prepared the housing, potted the internal volume, and delivered the result expected by the customer.

Kyiv Industrial use Interface adapter Polyurea potting
Potted interface-conversion adapter housing filled with orange polyurea gel

The task was not to make a pretty enclosure. The task was to make a small adapter reliable enough for the factory floor. Empty space inside the housing would leave the electronics, pins, and solder joints exposed to vibration, mechanical shock, humidity, and thermal stress. The protection had to be physical, repeatable, and compatible with a compact connector body.

Customer context

DeviceCompact adapter for interface conversion, used as part of factory equipment.
EnvironmentVibration, handling drops, humidity, and warm operating conditions.
RiskConnector pin fatigue, cracked solder joints, moisture ingress, and intermittent field faults.

Engineering approach

We treated the adapter as a small mechatronic assembly, not just as an electronics part. The decision covered the compound, the potting process, connector clearances, fill behavior, cure behavior, inspection points, and future reproducibility.

  1. AssessHousing, pins, cavities, risk zones, and surfaces that must stay clean.
  2. SelectCompound route: compliant two-component polyurea instead of a rigid potting block.
  3. PrepareMasking, cleaning, orientation, and fixture logic before the pour.
  4. PotPour while low-viscosity so the material flows around pins and into voids.
  5. VerifyCheck fill, cured gel state, connector clearance, and customer-visible result.

Why polyurea fit this case

VibrationThe cured gel supports pins and small components while damping cyclic loads instead of transmitting them like a hard block.
HumidityThe compound fills the open volume and creates a continuous barrier around the electronics and connector entry points.
TemperatureThe selected material route remains suitable for warm equipment conditions, with the capability brief noting stability up to 130 °C.

Proof photos

Cured polyurea gel inside a small black housing
Cured compound inside the housing: filled volume, protected internals, accessible pins.
Polyurea gel surface around connector pins
Gel surface around pins: local voids are filled and entry points are sealed.
Connector pins encapsulated with polyurea gel
Pins supported by the gel: moisture protection without a brittle rigid block.

Result

The customer received the expected protective result.

The adapter housing was filled with the selected compound, the sensitive internal areas were protected, and the result matched the customer expectation for factory use. The case also gave us a repeatable potting route that can be reused for similar small housings, connectors, and industrial adapters.

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