Publish Time: 2020-09-22 Origin: Site
It‘s clear that advanced planning for any new development program (such as the wire to board connector is critical), and the failure to take heed of critical design details can wreak havoc on a development schedule.So you should know the right way to use wire to board connector
The article contains following:
Step1,Lap Solder
Step2: Wrapped Wire And Soldered
Step3: Intermediary PCB
Step4:The overmold
A lap-soldered connection is a common type of soldering operation that is ideally suited for low-complexity designs with benign environmental requirements. To perform this, the surfaces must be cleaned, and the cable insulation must be stripped, leaving an overlapping section of the header pin and the bare cable conductor. The two members are then soldered together to create the electrical connection; the solder acts as a pseudo-weld to provide strength.
Lap-soldered connections are feasible since the header pins and bare conductor can easily overlap one another, creating the framework to quickly perform the lap-solder operation. Heat shrink tubing can then be applied to the exposed conductors, providing a means of electrically insulating the components.
Why this is important: Lap-soldered connections are best for applications with no or minimal movement. Using different types of heat shrink (thickness, adhesive lined) offers slight improvements to pull strength and motion.
The wire AWG size will also impact this since only small AWG sizes can be used to coil around the header pins.
Like the lap-soldering process, using a wrapped wire and soldered connection is another technique to consider when attaching a bare wire conductor to a PCB-mounted connector pin. Instead of using an overlapping section of conductor and header pin, the bare wire is wrapped around the header pin like a post. Typically, one to four wraps are necessary before applying solder. This type of connection is stronger than a lap-soldered connection, since the wire is coiled around the header pin before soldering.
This process contains more components, more operations, and is more expensive. The intermediary PCB design solution is preferred when a high reliability or robust connection is needed.
If strength and reliability are critical, both lap-soldered and wrapped-wire connections are not appropriate for the application. Assuming there is physical space, the addition of an intermediary circuit board is the best option for a robust design solution. A low-complexity PCB of typically one or two layers would need to be designed in a way that would allow the header pins to be affixed and soldered. The PCB would be designed such that the header pin traces would electrically connect to corresponding plated through holes, and then soldered to the bare conductors of the cable harness. Next, the intermediary PCB must be electrically insulated and encapsulated for strength.
Overmolded connectors require hard tooling to be designed and built and provide exceptional strain relief and electrical insulation for the delicate connections discussed in this post.
The first step is to design an inner mold of a high durometer and electrically insulating material. The design intent of the inner mold is to provide a high strength means of encapsulating the components. The outer mold is typically a softer material and provides both strain relief and a cosmetic surface.