Several Design Ideas for Electronic Connectors

The importance of connectors in electronic systems is often underestimated. Many electronic system designers have had similar experiences: using the cheapest connectors often leads to higher costs in the end. Errors in selecting and using electronic connectors can cause system malfunctions, product recalls, product liability cases, circuit board damage, rework and repairs, which can lead to sales and customer losses. Therefore, when designing electronic products, do not underestimate the importance of connectors, otherwise it will only cause small losses and great losses, and it is important to choose a suitable connector for electronic devices.

So, how to choose electronic connectors? While cost factors are considered in the design, attention should also be paid to high-quality and highly stable products, as well as the design features of the connector itself. Innovative designs in connectors can provide some reference for electronic designers in the following aspects:

The dual-pole design concept of electronic connectors

Figuratively speaking, the dual-pole design can be said to "kill two birds with one stone." Optimizing the terminal design adapts to high-speed signal transmission and provides higher directional tolerance. In comparison to inductance, capacitance, and impedance, dual-pole terminals are structurally designed for high-speed applications and are minimized and optimized for minimum intermittence. Multiple electronic connectors can be placed on the same circuit board without plug and short circuit problems, and there is no need for a large number of signals on a single connector. The simple wiring of the dual-pole design saves space, makes the connectors smaller, and simplifies the detection of soldering pins. For example, 12 connectors can be placed on one board. It also reduces rework costs. Actual applications include telecommunications terminal user equipment, etc.

Electronic connector assembly process with no bending pin design

Improper handling of traditional punching can cause bending or deformation of pins, and the bending process can cause capillary cracks, which is unacceptable for the long-term performance of the product and can also affect circuit performance and costs. Electronic connectors use direct punching of angle, and punching terminals can avoid capillary cracks caused by the bending process, ensuring complete mechanical and electrical connections. The co-planarity of pins is 100%, controlled to within a tolerance of ±0.05mm, and the 100% surface-mounted pin co-planarity detection ensures the reliability of the circuit board assembly process and ensures good soldering, improving the product yield rate and reducing costs.

It also improves the ruggedness of the right-angled connector and prevents different electronic connectors from being damaged due to improper operation, which can be described as "unbreakable."

High retaining force surface design of electronic connectors

For SMT products, it is generally believed that the holding force on the board is poor. Does the surface-mounted PCB holding force have to be lower than that of through-hole connections? The answer is: not necessarily.

Improved design can effectively improve the holding force of the PCB. If the welding bracket, microholes of the surface-mounted pin, and large solder pad are superimposed, the holding force can be improved. Even I/O connectors can use surface-mounted pins. This can be metaphorically compared to "falling to the ground and taking root."

Rugged design of electronic connectors

To determine the reliability of connectors while allowing the use of flat pressing tools, the boards are fixed on the shell to improve ruggedness and achieve superior manufacturing processes, and increase production output. To sum it up in one word, it is "rock solid." Concrete applications include positron emission tomography scanners and embedded systems for railway vehicles.

Design of high-current, small-pitch electronic connectors and advanced locking mechanism

High-current, small-pitch design of electronic connectors

With the requirement for miniaturization of automotive electronics and consumer electronics, the design idea of high current and small pitch requires consideration.

Advanced locking mechanism of electronic connectors

The dual-lock design meets different needs: the forward lock design is suitable for high vibration applications, and it is very suitable for automotive and subway applications. The friction lock is designed for general vibration applications. The dual-lock design provides double safety protection, ensures reliable connections, and does not require special tools for on-site disassembly (maintenance/replacement) of cables.

Sunkye Connection Technologies provides a wide product portfolio with a complete interconnect solutions offering. Sunkye connectors and cables assemblies are complementary with Sunkye backshells and conduits.