Seven Suggestions for Connector Development

Seven Suggestions for Connector Development

1. Consider connectors early in design

Engineers often focus too much on the design of the entire system and put connectors in the final stage of design, "said Mitch Storry, Director of Product Development Engineering at TEConnectivity." They think connectors are simple, so they can put the relevant design in the final stage. Then they get stuck with their own design

We have seen too many stories of designers rushing to design connectors in the final stage of design. He told us that in many cases, designers have to choose non-standard connectors to complete the design, which not only increases costs but also delays delivery time.

To avoid such problems, relevant experts suggest that in the early stages of design, you should consider the connectors you use and reserve design space for them, and the design should also revolve around them.

No one listens to you saying 'first, decide the connectors you need', "said Stephen T. Morley, a product development engineer at TEConnectivity." But if they really do, they can actually save a lot of time and trouble

2. Understand the limitations of space

Although the thickness from microplate to board connectors is usually less than 1 millimeter, they are typically used for tightly packed applications. To address potential packaging issues, designers need to consider the wiring on the PCB board and the additional wires connected to the connectors. Due to the small spacing, you must make the lines and wires narrower, "said Mike Higashikawa, Regional Product Manager at Molex.

Furthermore, please remember that some connectors, such as flexible cable connectors, offer options for flipping forward and backward. When designing the system, you need to consider these flipping methods. For example, if there is another component before and after the connector flipped backwards, it may not be easy to access.

Finally, designers also need to note that surface mounted devices sometimes cannot handle smaller components. In some cases, they need a new vacuum nozzle to solve these problems.

3. Understand the current load capacity

As the size of the connector decreases, the current carrying capacity of the connector also decreases. Generally speaking, micro connectors can handle currents between 200mA and 500mA, which is almost half the rated current of board to board connectors. In order for the teacher to increase the number of terminals, the designer may need to increase the number of terminals.

4. Consider the stability of small/micro connections

I need advice to ensure that they are not damaged not only during the design phase, but also during the assembly process, "said TEConnectivity's Morley.

Morley, a micro connector design expert in RF applications, recalled that he designed military design experts. In space applications, half of the connectors were damaged during the testing phase.

If we don't take this issue to heart first, it may push up costs, he said. Damaged connectors require reconfiguration, decoration, and labeling. Even more expensive on-site replaceable connectors may be needed, and this change may extend the design time by one to two weeks.

Morley said, "It should be noted that always prioritize existing connectors. If these connectors are not compatible with your design, then consider your own design, which can save you a lot of time

5. Consider replaceability

If the appearance of the product is enclosed, then you need a connector that can be replaced from the outside. Otherwise, you need to do some welding work.

The more you do, the more proficient your welding and other skills become, but the higher the risk of damaging the entire system, "Morley said

6. Understand the functional requirements of connectors

Suppliers need customers to fully express their needs, otherwise they may misunderstand their needs. This is particularly important when manufacturing custom connectors.

Accurate clarification of connector requirements is crucial, "Storry said." If the expression is unclear or there are omissions, we may overlook key design requirements

7. Considering mechanical stress

Temperature, shock, and vibration can generate stress between interfaces and circuits. Experts suggest that you choose a connector that can avoid these forces.

I saw fragmented solder joints on some PCBs on the board, "Morley said." When the connector is firmly connected to the board or external structure, it must be able to withstand the forces of impact and vibration, otherwise cracks may occur