Poor contact
The internal metal conductor within the terminal is the core component of the terminal, which transmits voltage, current, or signals from external wires or cables to the corresponding contact pieces of the mating connector. Therefore, the contact pieces must possess excellent structure, stable and reliable contact retention, and good conductivity. Poor structural design of the contact pieces, incorrect material selection, unstable molds, oversized machining dimensions, rough surfaces, and unreasonable surface treatments such as heat treatment and electroplating, improper assembly, harsh storage and usage conditions, and improper operation can all lead to poor contact at the contact and mating parts of the contact pieces.
2. Poor insulation
The role of insulators is to maintain the correct positioning and arrangement of contact pieces, as well as to provide insulation between the contact pieces and between the contact pieces and the housing. Therefore, insulators must possess excellent electrical, mechanical, and molding properties. Particularly with the widespread use of high-density, miniaturized terminal blocks, the effective wall thickness of insulators has become increasingly thin. This poses stricter requirements on insulating materials, injection mold precision, and molding processes. Due to the presence of metallic excess, surface dust, soldering flux, and other contaminants becoming damp, as well as the fusion of organic material precipitates and harmful gas adsorption films with surface water films to form ionic conductive channels, moisture absorption, mold growth, aging of insulating materials, and other factors, these can lead to short circuits, leakage, breakdown, and low insulation resistance, among other poor insulation phenomena.
3. Fixed Malfunction
Insulators not only provide insulation but also typically offer neutralization and protection for protruding contact parts, while also serving as an installation positioning and locking mechanism for securing them to the equipment. Poor fixation can lead to issues ranging from unreliable contact and momentary power outages to the disintegration of the product. Disintegration refers to the abnormal separation between the plug and socket, or between the pins and holes, when the terminals are engaged, due to reasons such as material, design, or manufacturing. This can result in severe consequences, such as interruptions in power transmission and signal control within the control system. Poor fixation can be caused by unreliable design, incorrect material selection, inappropriate molding processes, poor heat treatment, inadequate molds, substandard assembly, and improper soldering, among other factors.
In addition, common issues include poor appearance due to reasons such as peeling coatings, corrosion, dents, sharp edges on plastic shells, cracks, rough machining of contact pieces, and deformation, as well as poor interchangeability caused by oversized mating dimensions of locking mechanisms, poor consistency in processing quality, and excessively high total separation force. These types of failures are typically easily identified and removed during inspection and use.
