Molex, a global leader in complete interconnect solutions, showcased its innovative technologies at the 2012 electronica China Innovation Forum. Among the highlights was the introduction of compliant needle technology—a revolutionary approach to electrical connections that eliminates the need for soldering. This technology is particularly useful in applications where reliability and durability are essential.
The compliant pin is designed to create a secure, solderless connection by deforming slightly when inserted into a plated through-hole (PTH). This deformation generates residual stress, which provides a strong mechanical hold. Originally used in telecommunications backplanes since the 1970s and later in consumer electronics during the 1980s, Molex pioneered its use in the automotive industry, bringing this advanced solution to new markets.
Today, Molex produces around 300 million compliant needles each month, accounting for approximately 30% of the company’s global connector production. The technology offers numerous benefits, including permanent and reliable connections that can withstand shock and vibration. It supports both single- and double-sided PCB mounting, making it ideal for SMT or via-based designs. Additionally, it works well with tin and tin/lead PCBs, allowing for pre-testing of component integrity before final assembly.
One of the key advantages of compliant pins is the elimination of thermal stress, which allows the use of standard plastics instead of high-temperature materials. This reduces costs associated with selective soldering and ensures a cleaner, more consistent finish. There's no flux residue, slag, tinning, or cold soldering issues, and the connectors are free from harmful lead content.
The most popular type of compliant needle is the Eye of the Needle (EON), known for its cost-effectiveness and ease of use. Made with Molex proprietary alloys, EON pins are simple to manufacture and install, requiring minimal tools and control. With over nine years of experience in automotive applications, Molex has developed comprehensive design guidelines based on real-world data and lab testing.
EON connectors are widely used in various automotive systems, including body electronics, powertrain, telematics, infotainment, airbag modules, engine compartments, gearboxes, and anti-lock braking systems (ABS). Current models like EON1.0, EON1.45, and EON1.80 are commonly found in sensor modules, transmission control units, power distribution boxes, and power system controllers. In all cases, the PCB with components installed can be tested first, ensuring quality before the compliant pin is added.
This technology not only enhances performance but also streamlines the manufacturing process, making it a valuable solution for modern electronics and automotive applications.
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