2023-08

1. The anti-corrosion function of connector coatings. The primary consideration in the production of connectors is corrosion resistance. The contact springs of electronic connectors are mostly made of copper alloys, which are prone to corrosion in typical working environments, such as oxidation and sulfuration. In fact, contact coatings are used to isolate the contact springs from the working environment to prevent copper corrosion. Optimizing the interface is an important factor in selecting suitable contact coating materials as a key function of corrosion protection. 2. Connector coatings help improve mechanical performance. The parameters related to mechanical performance mainly affect the durability or wear of the coating and the bonding strength. These factors represent two different perspectives under the same basic effect, namely the sharing of multi-point contact interfaces during relative motion, which can lead to cold welding. Important mechanical properties include the hardness, ductility, and friction coefficient of the coating material. All these properties depend on the inherent characteristics of the coating material and its processing methods. 3. Connector coatings help improve electrical performance. One of the main requirements for the electrical performance of connectors is to establish and maintain stable connector impedance. To achieve this, a metallic contact interface is needed to provide this inherent stability. The establishment of this contact interface requires that the surface film can avoid cracking during the contact and fitting process. 4. Connectors are characterized by being coated with precious metals. The essence of precious metal coatings (such as gold, palladium, and their alloys) is that they are to varying degrees free from the surface film. For these coatings, establishing metal contact at the interface is relatively simple, as it only requires the mating surface to move during fitting. To maintain the stability of the contact interface impedance, connector design requires that the precious metal on the contact surface remains unchanged to prevent the influence of external factors such as contaminants, substrate metal diffusion, and contact wear.

2023-08-18

2023-08

The four major manufacturing processes of connectors are: 1. Injection Molding 2. Stamping 3. Machining 4. Assembly

1. Stamping. 2. Plating. 3. Molding. 4. Assembly. 1. Stamping: The manufacturing process of electronic connectors generally starts with stamping the pins. Using a large high-speed stamping machine, the electronic connector (pins) is stamped from a thin metal strip. One end of a large roll of metal strip is fed into the front of the stamping machine, while the other end passes through the hydraulic worktable of the stamping machine and is wound onto a roll. The roll pulls out the metal strip and rolls up the finished stamped product. 2. Plating: After the stamping of the connector pins is completed, they should be sent to the plating section. At this stage, the electronic contact surfaces of the connectors will be coated with various metal layers. Similar issues to those in the stamping phase, such as twisting, breaking, or deformation of the pins, may also occur during the process of sending the stamped pins to the plating equipment. 3. Molding: The plastic housing of the electronic connector is made during the molding phase. The typical process involves injecting molten plastic into a metal mold and then quickly cooling it to form. Some defects include filling or partial blockage of the insertion holes (which must remain clean and unobstructed for proper insertion with the pins during assembly). Since backlighting can easily identify missing parts of the housing and blocked insertion holes, the machine vision system used for quality inspection after molding is relatively simple and straightforward. 4. Assembly: The stage of manufacturing electronic connectors is the assembly of the finished product. There are two ways to connect the plated pins with the molded housing: individual insertion or combined insertion. Individual insertion refers to connecting one pin at a time; combined insertion connects multiple pins to the housing simultaneously. Regardless of the insertion method used, it is required to check all pins for defects and correct positioning during the assembly stage; another routine inspection task is related to measuring the spacing on the mating surface of the connector.

2023-08-18

The four major manufacturing processes of connectors are: 1. Injection Molding 2. Stamping 3. Machining 4. Assembly

2023-08

What are the basic performance characteristics of board-to-board connectors?

The basic performance of board-to-board connectors can be divided into three main categories: mechanical performance, electrical performance, and environmental performance. 1. Mechanical performance: In terms of connection functionality, insertion and extraction force is an important mechanical performance metric. 1.1. Insertion and extraction force are divided into insertion force and extraction force (the extraction force is also known as separation force), and the requirements for the two are different. Relevant standards specify a maximum insertion force and a minimum separation force, indicating that from a usage perspective, the insertion force should be low (thus there are low insertion force LIF and zero insertion force ZIF structures), while if the separation force is too low, it will affect the reliability of the contact. 1.2. Another important mechanical performance metric is the mechanical lifespan of the board-to-board connector. Mechanical lifespan is essentially a durability indicator, referred to as mechanical operation in the national standard GB5095. It is defined as one cycle consisting of one insertion and one extraction, and the assessment is based on whether the connector can still perform its connection function (such as contact resistance value) after a specified number of insertion and extraction cycles. The insertion and extraction force and mechanical lifespan of board-to-board connectors are related to the structure of the contact elements (the magnitude of the normal force), the quality of the coating at the contact points (the coefficient of sliding friction), and the dimensional accuracy of the arrangement of the contact elements (alignment). 2. Electrical performance mainly includes contact resistance, insulation resistance, and dielectric strength. 2.1. Contact resistance: A high-quality electrical connector should have low and stable contact resistance. The contact resistance of connectors ranges from a few milliohms to several tens of milliohms. 2.2. Insulation resistance: This measures the insulation performance between the contact elements and between the contact elements and the housing, with values ranging from hundreds of megaohms to thousands of megaohms. 2.3. Dielectric strength, also known as voltage withstand: This characterizes the ability of the connector's contact elements or the contact elements and housing to withstand the rated test voltage, which depends on the gap between circuits (i.e., the spacing between contact elements and creepage distance) and the insulating materials used in the connector.

2023-08-18

What are the basic performance characteristics of board-to-board connectors?

2023-08

How should the performance of connectors be tested?

Connectors are devices that connect two active components. In practical applications, one may encounter connector failures or other fault issues. When faced with such problems, it prompts us to reflect on where the issue lies, which brings us to the topic of connector testing. If testing is done well, subsequent work can proceed smoothly, and such issues can be greatly avoided. With the rapid development of smart devices, connectors are widely used in various devices. They are components that electronic engineers and technicians frequently encounter, serving as a bridge for communication in electronic circuits. Proper transmission ensures the normal operation of all device functions. The forms and structures of connectors are diverse, varying according to application objects, frequency, power, application environment, and more. To improve reliability, the production process of connectors will undergo a final inspection to ensure product quality. Connectors consist of terminal housings and pin sockets, and are generally divided into pre-assembly and post-assembly inspections. 1. Pre-assembly inspection: The content of pre-assembly inspection includes: material shortages, burrs, shrinkage, deformation, color differences, dirt, blockages, indentations, uneven/deformed baffles, raised locking points, sagging/tilting or breakage, incorrect PIN markings/no PIN markings. 2. Post-assembly inspection: The content of post-assembly inspection includes: checking for gaps between copper/iron shells and plastic shells, deformation of iron/copper shells, latches not pressed into place, tilting, damaged plastic shells, improperly installed left and right hooks (inconsistent exposed dimensions of hooks at both ends), pressing the hooks a few times to confirm whether the left and right hooks are normal and elastic. Contact pressure check: The reliability of a connector, to a certain extent, depends on the contact pressure of its contact pairs. It is an important indicator that can directly affect the size of contact resistance and the wear of the contact pairs. In most structures, directly measuring contact pressure is quite difficult. Therefore, it is often indirectly calculated through single-pin separation force. For circular pinhole contact pairs, a standard insertion pin with a specified weight is usually used to test the ability of the female contact to hold the weight. Generally, the diameter of the standard insertion pin is taken as the lower limit of the diameter of the male contact. The total separation force is usually twice the sum of the single-pin separation forces. When the total separation force exceeds 50N, manual insertion and removal become quite difficult. Of course, for some testing equipment or certain special requirements, zero insertion force connectors or automatically disconnecting connectors can be selected.

2023-08-18

How should the performance of connectors be tested?

2023-08

Terminal materials of connectors

2023-08-18

2023-08

How to distinguish between male and female connectors?

The male and female ends of a connector can be distinguished by the following aspects: 1. Appearance: Typically, the male and female ends of a connector have different shapes. Generally, the male connector's housing may be larger and have protruding or raised parts, while the female connector's housing may be smaller and have corresponding grooves or holes. 2. Ports and Pins: Male connectors usually have ports (pinholes) designed to receive the pins from female connectors. In contrast, female connectors typically have pins (inserts) that are inserted into the ports of male connectors. 3. Locking Mechanism: Some connectors feature special locking mechanisms to ensure a secure connection. These locking mechanisms may vary slightly between the male and female ends. For example, the male connector may have a rotating lock or a push-lock, while the female connector may require rotation or pressing to insert or remove. 4. Markings: Certain connectors may have markings indicating the male and female ends, such as 'M' for male and 'F' for female. These markings can help users quickly identify the male and female ends of the connector.

2023-08-18

How to distinguish between male and female connectors?

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