Patent ID: 8226872

Claim:
A method for making a molded item, comprising: providing a wire set including an outer sheath surrounding a plurality of wires, the outer sheath having an outer surface; applying a polyurethane bonding material to at least a portion of the outer surface of the outer sheath; positioning at least the portion of the wire set with polyurethane bonding material within a mold cavity of a molding die; overmolding the portion of the wire set within the molding die to form the molded item, wherein the overmolding includes filling the mold cavity with molten material and covering substantially all of the polyurethane bonding material with the molten material, the molten material producing an amount of heat and being configured to harden into overmold, wherein the heat operates to activate the polyurethane bonding material to bond the wire set with the overmold within the molded item with substantially all of the polyurethane bonding material being encompassed by the overmold.