To avoid wasting time for customers, custom plug connectors are the most suitable way

Plug connectors are available in a variety of options such as number of electrodes, plating and orientation, soldering techniques, mounting or assembly aids. As a result, each product line can have more than 1,000 models, no wonder the supplier will not provide all products in accordance with the standard model. However, custom products can be value for money.

      Many plug connector suppliers now design their products in a modular fashion based on the LEGO principle, enabling them to offer a full range of products that cover many specific requirements. In this regard, customers have no tool costs. But the downside is that if the supplier uses the tool to produce a model, it is not possible to produce a similar model during this period. Therefore, customers should always pay attention to the minimum order quantity (MOQ) and delivery time.

Tailored plug connector

      If you decide to make changes based on your specifications, the first step is to contact the plug connector supplier. Based on the number of orders, technical possibilities, and the use of the supplier's machines and business strategy, the supplier decides whether the customer's requirements can be met.

      In the process of this change, it is worth considering whether the weakness can be eliminated and the subsequent process is optimized. Modifications to the stamped portion of the plug connector, such as length, shape, plating or bending, are generally sufficient. Another type of carrier material, such as high temperature plastic or two component injection molded components, can also make a significant difference in design. A snap-in lug or P&P area may be present and the package can be adjusted in size and shape. Modifications to the package, such as reels and pick and place covers, larger package units, carriers or reusable packages, simplify and speed up the procurement and production process.

      In general, 2D information in a PDF document is sufficient for such changes. Experience has shown that additional costs range from a few hundred euros to several thousand euros. These costs only occur once, and the supplier will consider other factors in the component price.

KR3000 series connectors---Automobile connectors

No half way

      When a company decided to use a tailored plug connector, the problem occurred:

      Why not choose a true individual plug? Today, many special requirements can be easily implemented, for example:

      • Complex packaging that has long been sealed with a two-component injection molding

      • Package with welded pressure compensation film, using ultrasonic to ensure water tightness

      • Pressure contact points to eliminate the welding process

      • Combine multiple technologies such as IDC and press fit

      • Connector face is part of the application package

      • Two or more combined connector faces

      • Connection bridge integrated in the contact (power range)

      • Other products, such as electrolytic capacitors or coils, have long been in contact in the package

      • Implemented busbars

      • Molded ground connection, mounting bracket, isolation bolt or screw bushing

      Simply integrate these difficult components and processes.

      Miniaturization by laser direct structuring

      Laser Direct Forming (LDS) is a good choice when “miniaturization” is the primary goal of the design. Thanks to this technology, circuits can be drawn on various RoHS-compliant plastic materials and the circuit diagram can be modified using a 3-axis laser. In high-volume production, cables and pitches as thin as 0.10 mm and circuit grids of 0.35 mm can be achieved. In addition, a variety of design features are available. The LDS integrates with fixed contacts, laser drilling and tiny deflection holes with a diameter of only 50 μm, structural components such as cantilever contacts and integrated switch contacts, and antenna design connections. Due to the thick copper plating, an effective heat sink or EMI shield connection can be developed.

      The production process of the plug connector is fully automatic. LDS and the above modifications require tools that can cost hundreds of thousands of euros. In this case, the customer should share some expenses. This tool is usually still the property of the supplier to protect the proprietary technology that has been incorporated.

      In order to meet such complex requirements, the plug connector supplier needs a 3D file upon receiving an inquiry, preferably in a common format (.stp, .igs, .dwg, etc.). Often, the development and design of the plug connector is not the responsibility of the supplier, but the responsibility of the customer. However, suppliers often provide advice in this regard.

      The profitability of this decision can be shown by cost-benefit calculations. The savings in other components and production processes may exceed the additional cost of custom-designed plug connectors. Moreover, companies can use plug connectors to create applications with unique selling points and competitive advantages. The question of whether or not the goal can be achieved in individual cases is not easy to answer, and this needs to be considered separately. Here, a complete analysis of the total cost of ownership is especially important.

      The time frame for such projects, from concept to production part approval process (PPAP) sampling, is estimated to be approximately six months. Therefore, it is especially important to choose the right partner from the start. Russell can provide strong support to customers in this regard: Russell understands its supplier's product portfolio, manufacturing facilities, technology and equipment, and can evaluate whether the corresponding plug connector supplier can meet the customer's product requirements. Avoid customers wasting time chasing unrealistic solutions to get the ideal plug connector product that meets design requirements as quickly as possible.

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