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The connector divides the specification requirements into four parts according to its product function and usage environment
1. Electrical specification requirements
2. Mechanical specification requirements
3. Environmental Specification Requirements
4. Environmental requirements
First, electrical specification requirements
Electrical characteristics are the main characteristics of the connector to achieve the connection function. Determine the electrical characteristics of the connector to ensure that the connector meets the connection function. The electrical characteristics of the connector are:
1. Contact Resistance
Purpose: To maintain the contact impedance of the connector during its service life to reduce the loss or attenuation of signals and energy during transmission.
Test Method: EIA-364-23 (EIA-364-06) or MIL-STD-1344A,3004.1.
Test points: a. The test current/voltage is 100mA@20mV, and the tested connector (connection system) has no load.
b. The test current is low to avoid the contact resistance being affected by the thermoelectric effect of the terminal (conductor).
c. The test voltage is low to avoid breakdown and melting of the contact interface insulating film between the terminals (conductors).
Specification requirements: generally require 50m? (initial); 100m? (final, after life test or environmental test).
Define Contact Impedance This parameter is to reduce the loss or attenuation of signal and energy during transmission, current is like water flow. The less resistance, the less energy is lost and decayed.
As far as the contact of the connector is concerned, the factors that affect its impedance are the normal force (for the elastic contact structure), the contact environment, such as the terminal (conductor) Surface roughness, surface treatment (such as metal characteristics and density of electroplating), terminal and terminal (or other conductor) bonding method (is it welding or riveting or elastic contact, etc.).
From the point of view of electrical theory, the contact impedance is the impedance at the contact point of the green circle at point C; from the point of view of guest use, the connector provides conduction from point A to point B (connection), so the impedance requested by the guest should include the impedance of all conductors from point A to point B and the impedance at the contact point (including welding, riveting and other contact methods) as shown in Figure 1.
2. Withstanding Voltage
Purpose: To confirm whether the insulating medium (including gas) and its spacing between two conductors (or two loops) is suitable and sufficient to ensure that the connector can be switched during surge voltage or accidental It can maintain normal function under overload (overvoltage for a certain period of time) and ensure safety.
Test Method: EIA-364-20 or MIL-STD-1344A,3001.1.
Test points: a. Generally, the measurement point is placed between the two conductors (or two loops) closest to the distance, or two conductors (or two loops) are specified, and the measurement is necessary if necessary Every two conductors (or two loops).
b. The test voltage can be AC (60Hz; sine wave; RMS=0.707*peak) or DC.
c. Load speed: 500V/second; Duration: 60second.
d. Breakdown (spark) or leakage current greater than 5mA under the required test voltage is bad.
Specification requirements: mobile phone connectors are generally 100VAC Min./minute.
Define the withstand voltage This parameter is to ensure the safety of the connector under overload voltage. Avoid accidental overload to avoid short circuit, resulting in fire and other accidents.
The test results are related to many factors, including the test environment, such as air pressure and humidity; the applied pressure, frequency and duration of the test, electrode form; the frequency & waveform of the test voltage ; Product geometry (and stress); dielectric conditions and spacing between two conductors (or two loops), etc.
The withstand voltage value is generally set to 3 times the rated working voltage or 3/4 of the breakdown voltage. For mobile phone connectors, 100VAC Min./minute is sufficient. fulfil requirements.
3. Insulation Resistance
Purpose: To confirm that the impedance between the two conductors (or two loops) in the connector is high enough to prevent the generation of weak enough to affect the signal (especially high frequency transmission) and energy transmission. current.
Test Method: EIA-364-21 or MIL-STD-1344A,3003.1.
Test points: a. Generally, the measurement point is placed between the two conductors (or two loops) closest to the distance, or two conductors (or two loops) are specified, and the measurement is necessary if necessary Every two conductors (two loops).
b. The test voltage levels are DC 100V, 500V, 1000V, 1500 V; determined according to product functional requirements.
c. Duration: 2minutes (if time affects the result, determine the test duration).
d. If necessary, clean the test sample and bake it before testing.
e. There shall be no spark or insulator breakdown during the test.
Specification requirements: The mobile phone connector is generally 100M? Min..
Define Insulation Resistance This parameter is to reduce the influence of weak current on signal/energy transmission.
Insulation resistance has a particularly great influence on high-impedance circuits, and the insulation resistance value can determine the weak current generated by thermoelectric effect, electromagnetic induction, etc. The test voltage is generally the working rated voltage of the product. The test environment such as pressure, temperature, and humidity will affect the results.
4. Temperature rise
Purpose: To confirm the current carrying capacity of the conductor (loop) in the connector to ensure the safety of the connector under long-term load.
Test method: EIA-364-70.
Test points: a. The temperature change can be measured only when the entire circuit reaches thermal equilibrium under the load current.
b. The test current/voltage is rated working current and working voltage.
c. The duration of the loading current and voltage is based on the time required for the loop to reach thermal equilibrium.
Specification requirements: Under the environment of 25 degrees Celsius room temperature and 1 atmosphere of pressure, through the current of 1.5A@250VAC Min., the temperature rise of any point of the system conductor (loop) does not exceed 30 degrees Celsius.
The purpose of the temperature rise requirement is to avoid adverse effects caused by temperature rise (such as thermoelectric effects, accelerated elastic creep, etc.), maintain the function of the connector under continuous load and life, while avoiding the impact of elevated product temperatures on consumers. For example, the temperature of the surface of the mobile phone increases due to the prolonged use of the mobile phone, which makes consumers feel uncomfortable.
5. Contact Capacitance
Purpose: To determine the capacitance value between the conductors of the connector to avoid interference caused by current or signal penetration.
Test method: EIA-364-30.
Test points: a. The test frequency is generally 1k Hz or 1M Hz.
b. Generally, the measurement point is placed between the two conductors (or two loops) closest to the distance, or two conductors (or two loops) are specified, and each two conductors are measured if necessary (or two loops).
Specification requirements: The capacitance value is generally 2pF Max.
The connector will generate force during use. Determine the strength requirements of the connector to ensure that the connector can be firmly connected. The mechanical properties of the connector are:
1. Mating and Unmating force
Purpose: To confirm that the force generated by the connector during use is sufficient to maintain the connector function and feel suitable for consumers.
Test method: EIA-364-13 or MIL-STD-1344A, 2013.1.
Test points: a. The test object is the entire connector, full ass'y.
b. The test axis is the direction in which the connector is normally used.
c. Unless otherwise specified, the test speed is defined as 25.4mm/minute.
Specification requirements: a. The insertion force is generally set to the maximum value. (35N Max.).
b. The pull-out force is generally set to the minimum value. (7N Min. initial; 3N Min. Final), there are also customer requirements to set the maximum value.
The insertion force is defined to suit the consumer's hand feel, and the pull-out force is defined to ensure that the connector remains connected under the condition of unexpected force, and no accidental force is caused. The two connected products are disconnected and disconnected.
The insertion force is the force generated by the two matched connectors from completely separated to the working state; the pull-out force is the force generated by the two matched connectors from the working state to the complete state. The power of separation. The plugging force is generated when consumers use the product, and the plugging force is generated only when there is a butt end (io/plug, jack/plug). Generally, there is no butt end, such as battery/sim conn. The plugging force is not defined. (Refer to Figure 2)
The force curve graph produced during the testing process contains a lot of information. From the force curve graph, we can understand the stress state of the connection system during the plugging and unplugging process, and find out abnormal points for design. improve.
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2. Locking force
Purpose: To confirm that the contact interface is not separated when the connector is subjected to unexpected conditions (force) during use, so as to ensure the function under unexpected conditions (force).
Test method: N/A.
Test points: a. The test object is the entire connector, full ass'y.
b. The test axis is the direction in which the connector is normally used.
c. Unless otherwise specified, the test speed is defined as 25.4mm/minute.
Specification requirements: generally set the minimum value (30N Min.).
The locking force is the force generated when the locking mechanism is still working to force the two mating connectors from working to complete separation. This test is a destructive test, and the locking force in a self-locking or semi-self-locking system is equivalent to the pull-out force.
3. Retention
Purpose: To ensure the state (position) of the connector contacting the terminal (conductor) during manufacture or use, and to avoid external forces (such as pulling during wire bonding in the manufacturing process; Thermal deformation force; force during insertion and removal, force generated by shock or vibration during use, etc.) make the contact terminal (conductor) deviate from the working position, resulting in the loss of the connection function.
Test method: EIA-364-29 (EIA-364-05).
Test points: a. The test object is the entire connector, full ass'y
b. The test axis is the normal use direction of the connector (the opposite direction of the terminal assembly).
c. Unless otherwise specified, the speed is 25.4mm/minute.
e. is a destructive test.
Specification requirements: generally set the minimum value (4.9N Min.).
The terminal holding force is defined to ensure that the terminal (conductor) is fixed in the plastic, and the terminal that has been assembled in the plastic is pulled during the manufacturing process (such as welding/product handling). /SMT process) and use process (such as male and female mating process, or the product is subjected to vibration and shock) will receive external force, so the retention force of the terminal and the plastic must be sufficient, so that the terminal will not be generated after accidental force. If the PIN is withdrawn, the connection will be interrupted and the connection function will fail. (Refer to Figure 3)
Image
4. Normal force
Purpose: To maintain the positive contact stress of the connector during use, to ensure that the connector maintains a sufficiently low contact resistance and friction during use; to ensure the connection function (not momentary interruption).
Test method: N/A.
Test points: a. The positive contact stress generated by the elastic contacts in the system under working conditions.
b. Unless otherwise specified, the speed is 25.4mm/minute.
Specification requirements: generally defined between 60-150gf (within the working period).
The normal force of the elastic terminal is defined in order to maintain a low enough contact resistance and avoid the breakage of the product due to vibration or other unexpected forces during use.
The normal force refers to the force required to make the elastic terminal from the initial state to the working state (refer to Figure 4). It must be ensured that the normal force of the connector is in the life test or environmental test Keep it front and back enough.
The relationship between the normal force of the terminal and the contact resistance is a reciprocal relationship. When the normal force increases, the contact resistance decreases. When the normal force increases to 60gf, the magnitude of the decrease in the contact resistance becomes very small.
In addition, the greater the normal force, the greater the frictional force generated during the contact process (f=F*u; f----friction, F---- The normal force, u----friction coefficient), is more beneficial to the wear of the contact interface, so the general definition of the normal force does not exceed 150gf. (Refer to Figure 5)
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5. Durability
Purpose: To confirm that the connector meets the functional requirements within the service period.
Test method: EIA-364-09 or MIL-STD-1344A,2016.1.
Test points: a. The test axis is the normal use direction of the connector.
b. Unless otherwise specified, the speed is generally 200-500cycles/H.
c. There is generally no current load during the test. (unless otherwise requested).
Specification requirements: a. Parameters to be determined during and after the test: insertion force (or normal force), contact resistance (terminal or iron shell), insulation resistance, Withstand voltage, sealing, etc. meet the product specification requirements.
b. Visual inspection: wear, slack or fatigue, metal fragments, terminal displacement or bending damage, etc.
Life is also called durability (durability), which refers to the lifespan of a product. Usually defined as the number of uses, to evaluate the wear of the terminal plating and the change in mechanical/electrical characteristics before and after mating and unplugging after continuous use (mating or positive pressure) of the connector.
The force graph generated during the life test can analyze the change and trend of the insertion force before and after the life to assist design corrections. Before the life test, it is necessary to confirm that the sample has undergone a complete process. For example, the board end products need to pass SMT before entering the test process.
6. Cable Pull-out
Purpose: To ensure a stable connection between the cable and the connector, to avoid external force on the cable involving the connector and damage to the cable or connector
Test method: EIA-364-38.
Test points: a. Loading speed: 89 +/- 4 N/minute; Loading time: 1H.
b. General static load 40N for one minute (or according to Condition A-E).
Specification requirements: a. Visual inspection: the outside of the cable is damaged; the connector insulator or conductor is damaged; the cable clamp fails; the cable is separated from the clamp or the displacement exceeds the allowable value; the sealing of the cable to connector Sexual damage; connector metal body distortion, etc.
b. Function check: impedance; momentary interruption, etc.
Cable Pull-out This parameter is only for plug ass'y with cable, to confirm the appearance and function of the cable when it is pulled by external force. There are 90 degrees and 180 degrees in the direction of pulling force. If the customer wants special requirements, it will be in accordance with the customer's requirements.
7. Visual and Dimensional Inspection
Purpose: To confirm product (system) appearance and size quality.
Test method: EIA-364-18.
Test points: a. Appearance section defines personnel vision, lighting environment, sample placement, visual distance and time.
b. The size part defines measuring instruments and measuring methods, sample requirements, etc.
Specification requirements: a. Surface treatment requirements (such as plastic surface roughness; terminal plating), appearance requirements (such as no crushing; burrs).
b. The size conforms to the drawing requirements.
Other mechanical characteristics, the part of the connector that involves force during use, has mating stability (such as rocking up and down when the male and female are mated) and joint stability (such as the finished product) The drop resistance of the upper and lower shells), etc., should be added to the definition in the product specification when necessary.
3. Environmental Specification Requirements
The connector will encounter different environmental conditions during use, confirm the electrical characteristics or mechanical characteristics in different use environments, and ensure the function of the connector in different use environments. The environmental properties of the connector are:
1. Mechanical Shock
Purpose: To verify the ability of the connector to withstand unexpected physical shocks.
Test Method: EIA-364-27 or MIL-STD-1344A,2004
Test points a. Shock pulse: half-sine or sawtooth (the two have different acceleration peaks)
b. The sample has been fully wired and mated, and loaded with load, load: 100mA Max.
c. 3 times in each of the six directions on three mutually perpendicular planes, a total of 18 times
d. Generally used pulse, the peak acceleration is 30Gs, and the period is 11ms
Specification requirements: a. no discontinuities of one microsecond
Physical shock is the situation where consumers use the product under accelerated motion load, ensuring the connection function of the product under different acceleration environments.
2. Random Vibration
Purpose: To confirm the function of the connector under vibration conditions during use.
Test Method: EIA-364-28 or MIL-STD-1344A,2005
Test points: a. Sample placement; samples need to be full ass'y or install (simulated usage)
b. Vibration parameters: acceleration=9.81 m/s2, amplitude=1.52mm; frequency conversion amplitude & time & mode; duration, all need to be determined; < br />
c. The sample is loaded Load: 100 mA Max.
Specification requirements: a. no discontinuities of one microsecond
b. other dimensional, and functional inspection
Random vibration is to simulate the consumer's use of the product under vibration conditions (for example: using the product in a moving car), ensuring the product's connection function under different vibration environments.
3. Impact
Purpose: To ensure the ability of the connector to resist collision. In order to ensure the function of the system in the event of an accidental landing and other collisions.
Test method: EIA-364-42 (see Figure 1)
Test points: a. Concrete floor, H=0.1m Min.
b. Height and times (related to product requirement level)
c. Drop orientation
Specification Requirements: Failure Type
a. Loss of tightness
b. Loss of electrical function
c. Loss of mechanical properties (male-female fit; part structure)
Crash testing simulates a product being accidentally bumped. Ensure the connection function of the connector when subjected to accidental impacts such as grounding.
4. Thermal Shock;Temperature Cycling
Purpose: To ensure the normal application (storage; transportation; use) of the connector in extreme temperature (high or low temperature) environments
Test Method: EIA-364-32 or MIL-STD-1344A,1003.1
Test points: a. The sample needs to be determined as mating or unmating
b. The sample should have 75% exposed area in the greenhouse, and the transfer process between the two greenhouses should be insulated; the duration of the test is related to the weight of the sample.
c. The medium in the greenhouse is liquefied nitrogen, and the high temperature test conditions are: 85 to 88 degrees Celsius; the low temperature test conditions are: -55 to -58 degrees Celsius
d. The duration is generally 30 minutes; the default cycle is 5cycles (according to product functions or customer requirements)
Specification requirements: a. Sample size variation
b. Components are damaged or displaced (seals, electrical componentsetc.)
c. Sample elastic failure condition
d. Whether the electrical and mechanical properties of the sample have changed
e. For parts with specific requirements for high temperature or low temperature resistance, follow customer requirements
A temperature shock is a simulation of how a consumer would use a product under different temperature conditions, such as near the red or at the north and south poles. Make sure that the connector can be used normally under different temperature conditions.
5. Humidity
Purpose: To confirm the function of the connector in high temperature and high humidity environment
Test Method: EIA-364-31 or MIL-STD-1344A,1002.2
Test points: a. To avoid condensation on the sample, dry the sample before the test, drying conditions: 50℃, 24H
b. Test ventilation rate: 5 times the volume of the test space/minute; wind speed: 46m/minute Max.
c. Sample load during testing: 100VDC;
d. Test duration according to product functionality or customer requirements
Specification requirements: a. Sample size variation
b. Components are damaged or displaced (seals, electrical components, etc.)
c. Sample elastic failure condition
d. Whether the electrical and mechanical properties of the sample have changed
e. Comparison of parameters before and after humidity test
6. Salt Spray
Purpose: To confirm the function of the connector under salt mist air. It mainly evaluates the corrosion resistance (electrolytic corrosion) ability of connectors, especially surface-treated hardware.
Test Method: EIA-364-26 or MIL-STD-1344A,1001.1
Test points: a. Air jet requirements (gas, relative humidity, temperature, air pressure, relative concentration
b. Salt solution concentration: 5 +/- 1 % pH=6.5-7.2 Temperature: 35 +1/-2 ℃
c. Sample placement requirements, no salt water accumulation during the test
d. The test time is generally more than 8H for tin plating and more than 12H for gold plating (or according to customer requirements)
e. Wash and dry the samples after testing
Specification requirements: a. Corrosion status (the extent of damage to the protective layer)
b. Size variation
c. Whether the electrical and mechanical properties of the sample have changed
7. Solderability
Purpose: To ensure that the soldering area of the connector meets the soldering requirements.
Test method: EIA-364-52
Test points: a. Also called tin-eating, test with dip method
b. Not normally used to evaluate solder cups, solder holes, hand soldering, SMT
c. Pay attention to the temperature curve when evaluating whether it is suitable for SMT process
Specification requirements: a. 95% of soldering area eats tin
Defining solderability is to confirm the solderability of the product's soldered area (that is, the issue of soldering quality), and it is also necessary to define the solderability (that is, the issue of soldering duration). Because the soldering process generates heat, the heat can affect both the plastic and the terminal, possibly melting the plastic and reducing the terminal retention.
8. Flammability
Purpose: To confirm the flame retardant properties of the connector (mainly the plastic part)
Test Method: UL 94-V0;V1;V2;HB or EIA-364-104
Test points: a. Whether the sample is placed horizontally or vertically during the test
b. How long will the burning last if the sample burns away from the fire source
Specification requirements: a. Comply with UL fire rating (usually UL 94-V0)
The flame retardant grades increase from HB, V-2, V-1 to V-0.
Among them, the HB sample is placed horizontally, which is the lowest flame retardant grade in the UL94 standard. For samples with a thickness of 3-13mm, the burning speed is less than 40mm/min; less than 3mm thickness , the burning speed is less than 70mm/min; or it goes out before the 100mm mark.
V-2; After two 10-second burning tests on the sample, the flame was extinguished within 60 seconds, and burning objects could fall.
V-1; After two 10-second burning tests on the sample, the flame was extinguished within 60 seconds, and no burning objects could fall.
V-0; After two 10-second burning tests on the sample, the flame was extinguished within 30 seconds, and no burning objects could fall.
Fourth, environmental protection requirements
Corporate activities must comply with local laws and regulations of production (such as safe production, disposal of waste gas/wastewater/waste/noise, etc.), laws and regulations of sales places (such as green product requirements) and customer request.
For products, enterprises must gather relevant local laws and regulations of production, relevant laws and regulations of sales places, and customer requirements, and formulate their green product strategies and related processes accordingly. , to ensure that the entire process from supplier feeding to in-house production to shipment meets the requirements.
Important laws, regulations and customer requirements related to connector products are:
1. WEEE, Waste Electrical and Electronic Equipment (WEEE) Directive (2002/96/EC), Waste Electrical and Electronic Equipment Directive. It is a directive issued by the European union on February 13, 2003 and formally required for implementation on August 13, 2005. The aim is to reduce the harm to the environment caused by the increasingly serious waste of electronic and electrical items in the world, and to reduce the production and disposal of waste electronic and electrical items through reuse, recycling and other operations. At the same time, we want to improve the environmental performance of electronic and electrical items (including relevant economic performance in the life cycle of electronic and electrical items).
2. RoHS, The Restriction of the use of certain Hazardous Substances in Electrical and Electronic Equipment. It is a directive issued by the European union on February 13, 2003 and formally required to be implemented on July 1, 2006. The main goal is to limit the use of hazardous chemicals on electrical and electronic items to promote recycling and final disposal of electrical and electronic items after they are discarded. The restricted substances required in the RoHS directive are lead Pb (<1000ppm), cadmium Cd (<100ppm), mercury Hg (<1000ppm), hexavalent chromium Cr6+ (<1000ppm), polybrominated biphenyls PBB (<1000ppm) , PBDE (<1000ppm)
3. REACH, REGULATION concerning the Registration, Evaluation, Authorizationand Restriction of Chemicals, "Registration, Evaluation, Authorization and Restriction of Chemicals", a directive adopted by the European union on December 13, 2006 and implemented on June 1, 2007, aimed at protecting human health and environmental safety, Maintain and improve the competitiveness of the EU chemical industry, as well as the innovative ability to develop non-toxic and harmless compounds, prevent market fragmentation, increase the transparency of chemical use, promote non-animal experiments, and pursue social sustainable development, etc.
4. SONY SS-00259, a technical document for sony's green partnership program. It includes defining the types, contents and relevant requirement levels of various hazardous substances, aiming to ensure that its products meet the requirements of laws and regulations by building a green supply chain, and become green products and sell to the world.
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