Common problems of power terminal board in use

The plastic insulating materials and conductive parts of the terminal are directly related to the quality of the terminal, which determine the insulation and conductive properties of the terminal. Failure of any power terminal board will lead to failure of the whole system engineering. The painful lessons at home and abroad in this regard are very profound.

Prevention is the purpose and analysis is the basis. In a sense, failure prevention is more important than failure analysis. It has more practical significance to ensure the quality and reliability of power terminal board

From the perspective of use, the power terminal board should achieve the following functions: the place where the contact part is connected needs to be connected, and the contact is reliable. Where the insulation part should not be connected, the insulation shall be reliable. There are three common fatal failure modes of power terminal board:

1. Poor contact

The metal conductor inside the power terminal board is the core part of the terminal. It transmits the voltage, current or signal from the external wire or cable to the contact corresponding to the connector. Therefore, the contact has excellent structure, stable and reliable contact retention force and good conductivity. Due to unreasonable contact structure design, wrong material selection, unstable mold, over poor processing size, rough surface, unreasonable surface treatment process such as heat treatment and electroplating, improper assembly, poor storage and use environment, and improper operation and use, poor contact will be caused at the contact position and matching position of the contact.

2. Poor insulation

The function of the insulator is to keep the contact in the correct arrangement and to insulate the contact from the contact and the contact from the shell. Therefore, the insulating parts have excellent electrical performance, mechanical performance and process molding performance. Especially with the wide use of high density and miniaturized power terminal board, the effective wall thickness of insulator becomes thinner and thinner. This puts forward more stringent requirements for insulating materials, injection mold accuracy and molding process. Due to the presence of metal residues on or inside the insulator surface, surface dust, flux and other pollution and moisture, organic material precipitates and harmful gas adsorption film fused with surface water film to form an ionic conductive channel, moisture absorption, mould growth, aging of insulation materials and other reasons, it will cause short circuit, leakage, breakdown, low insulation resistance and other undesirable insulation phenomena.

3. Poor fixation

The insulator not only insulates, but also provides precise neutralization protection for the extended contacts. At the same time, it also has the function of installation, positioning, locking and fixing on the equipment. Fixed bad, light impact contact reliable cause instant power failure, serious is product disassembly. Disassembly refers to the abnormal separation between plug and socket, between pin and socket caused by unreliable structure due to material, design, process and other reasons when the power terminal board is plugged in, which will cause serious consequences of power transmission and signal control interruption of control system. Due to unreliable design, wrong material selection, improper selection of forming process, poor process quality of heat treatment, mold, assembly, fusion, etc., and improper assembly, poor fixation will be caused.