One, poor contact

The metal conductors inside the hardware pressings, hardware terminals, and wiring terminals are the core components of the terminals. They transfer the voltage, current, or signals from external wires or cables to the corresponding contacts of the connector to which they are matched. Therefore, the contacts must have excellent structure, stable and reliable contact retention force, and good conductivity. If the structure design of the contacts is unreasonable, the material selection is incorrect, the mold is unstable, the processing dimensions are out of tolerance, the surface is rough, the surface treatment processes such as heat treatment and electroplating are unreasonable, the assembly is improper, the storage and usage environment is harsh, and the operation and usage are improper, contact failure will occur at the contact and mating parts.

II. Insufficient Insulation

The function of insulators is to keep the contact components in the correct position arrangement and to insulate the contact components from each other, as well as from the housing. Therefore, insulating components must possess excellent electrical properties, mechanical properties and process forming capabilities. Especially with the widespread use of high-density and miniaturized connection terminals, the effective wall thickness of insulating components is becoming increasingly thinner. This poses more stringent requirements for insulating materials, the precision of injection molds and the forming process. If there are metal impurities, surface dust, soldering flux, etc. on the surface or inside the insulating component, and if the surface moisture film, organic material precipitates and harmful gas adsorption films fuse with the surface water film to form ionic conductive channels, causing moisture absorption, mold growth, insulation material aging, etc., these will all lead to insulation failure phenomena such as short circuits, leakage, breakdown, and low insulation resistance.

III. Fixed Defects

Fixing problems improperly can lead to various consequences. In mild cases, it can affect the reliable contact, resulting in a momentary power outage. In severe cases, the product may even disintegrate. Disintegration refers to the abnormal separation between the plug and the socket, or between the pins and the holes, when the terminals are in the plugged-in state. This abnormal separation is caused by factors such as materials, design, and manufacturing processes, and results in serious consequences such as interruption of power transmission and signal control in the control system. If the design is unreliable, the material selection is incorrect, the forming process is improperly chosen, the quality of heat treatment, molds, assembly, fusion welding, etc. is poor, or the assembly is not done properly, all of these can cause improper fixation.

Metal stamping parts, metal terminals, connection terminals, due to reasons such as peeling of the coating, corrosion, damage, plastic shell burrs, cracking, rough processing of contact components, deformation, etc., resulting in appearance defects; and due to reasons such as exceeding the positioning and locking fit dimensions, poor consistency of processing quality, excessive total separation force, etc., resulting in interchangeability defects, are also common problems. These types of faults can generally be detected and eliminated in the inspection and usage processes.

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