Molex compliant needle technology offers many advantages

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. The **compliant pin** is designed to be flexible and provides a secure, solderless crimp connection to the substrate. When inserted into a plated through-hole (PTH), the pin deforms slightly under pressure, creating a holding force due to residual plastic stress. This technology has been widely used in telecommunications backplanes since the 1970s and in consumer electronics during the 1980s. Molex was among the first to apply this technology to the automotive industry, where it now plays a crucial role. Today, Molex produces around 300 million compliant needles per month, accounting for approximately 30% of the company’s global production. The compliant pin crimping method offers significant benefits, including permanent and highly reliable connections that can endure shock and vibration. It allows for double-sided PCB mounting using SMT or via technology and is compatible with both tin and tin/lead PCBs. Additionally, the PCB with components can be tested before connecting the compliant pin, ensuring quality and performance. One of the most popular types of compliant needle is the **EON (Eye of the Needle)**, which is easy to manufacture and uses Molex's proprietary alloys. It is the most cost-effective option, offering high reliability, ease of installation, and minimal tooling requirements. With over nine years of experience in automotive applications, Molex has developed comprehensive design guidelines for EON connectors based on lab data and real-world use. In the automotive sector, EON compliant pins are used in body electronics, powertrain systems, telematics, infotainment units, airbag control modules, engine compartments, gearboxes, and anti-lock braking systems (ABS). Current models like EON1.0, EON1.45, and EON1.80 are widely used in sensor modules, transmission control units, power distribution boxes, and power system control modules. A major advantage of the EON connector is that it doesn’t require soldering, reducing thermal stress and allowing the use of standard plastics. This eliminates the cost of selective soldering and ensures no flux residue, slag, tinning, or cold solder joints. It also avoids harmful lead, making it an environmentally friendly solution. By eliminating the need for soldering, the EON technology simplifies the manufacturing process while maintaining high-quality standards. It’s a perfect fit for modern automotive electronics, where reliability, efficiency, and sustainability are key priorities.

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