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  • Author Author: rscasny
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Poll: How Can Connectors Be Improved?

Improve. Diversify. Innovate. Evolve. I see these terms applied to the current trends in connector technology nearly every day. Connectors are faster, smaller, offer more protection, more durable and can handle higher currents in a smaller package. There are explosion proof connectors, switch-rated connectors and smart connectors. Connectors will continue to evolve...but how?

 

In what area do you see a need for connectors to improve?

  • in reply to 14rhb

    I'm now thinking of visiting the scrapyard with:

    • screwdriver
    • cutters
    • £1
  • in reply to shabaz

    It's depressing that consumer gear uses low-quality connections and wiring, or doesn't secure cables properly

    Agreed as they are supposed to be the design authority on such devices, and made worse by the fact the other 1/4" blade connectors I looked at in his cooker are really difficult to separate. I've loaned my DVM/thermocouple to the guy so he can measure the temperature in the back next time he has a roast or similar: I suggested having a look when the oven cavity had been running at about 200 degrees centigrade for 30 minutes or longer. Hopefully I'll manage to determine some suitable cable based on that. I know the sort of cable insulation you mean as well it is also a bit tougher to cut. Thanks for your help.

     

    This cooker appeared to have some heat resistant flex between the wall outlet and hardwired into the screw terminals but as it was physically low down it would likely be exposed to lower temperatures. I've found some super high temp cables that have fluoropolymer insulations and can operate at 300 degrees C - but a bit expensive as I'd have to buy a whole real just for a 400mm rewire image. Silicone goes to 180 degrees C so might be a good choice to track down a small section of. As you say there are other exotic materials so I'll keep looking.

     

    Coincidentally I purchased some of the glass-fibre sleeving you mention for him as well,  a "belt-and-braces" approach should the insulation still start to soften at temperature - so good to know I'm along the right lines.

  • in reply to 14rhb

    Hi Rod,

     

    It's depressing that consumer gear uses low-quality connections and wiring, or doesn't secure cables properly : (

    I'm not entirely sure, because there are specs (paid ones) to check for product wiring, and I don't recall what specifics there are for high temperature applications.. but when I was researching for a home-built reflow oven, I did purchase specific heat-resistant cable, it looked like usual blue/brown mains flex cores, but slightly stiffer - it could have glass fibre in there. Anyway, there's also glass-fibre sleeving, which can be put around the cable, where it is close to hot metal.

    Depending on how exotic a solution is needed : ) there's other materials too.

  • in reply to kmikemoo

    Hi - good point. What connectors have you used in the past and what difficulties have you had?

     

    The crimp ethernet plugs are nice and simple and some electrical connectors use pushfit recepticles after the wires are stripped. The old IDC/ribbon cables were nice and easy as well.

    I did work for a while wiring industrial units together and you had to make sure you cued the correct end of the multicore cable for the plug/socket otherwise everything ended up crossed over....and those connectors were solder buckets so invariable I ended up with hot fingers image

  • Make a connector that is reasonable easy to connect the wire to. <- That's what I want.

  • I am interested in connectors that are robust and easy to use by a maker.

     

    DAB

  • comment about heat made me think,

     

    A friend showed me their cooker some weeks ago which has developed many faults over the years - I'll withold the manufacturer's name so as not to get in a legal battle. The cooker uses nothing more complex than the old style 1/4" blade connectors but IMO after talking to them that is where most of the faults have started. The 1/4" blade connector has become loose over time (perhaps cooker heating and cooling cycles) and starts to develop a higher resistance at that point. The connector heats up, chars slightly by arcing, resistance increases, it heats up more etc. Eventually the heat is travelling up the cable and melts the insulation until it finally either shorts or the conductors melt.

     

    You would think there was nothing to improve to the old design 1/4" blades but there obviously is still !

    image

    As you can see their cooker has wading insulation (the yellow wool to the top-left) between the heated compartment (at 220 degrees centigrade perhaps) to reduce the heat to the control wiring. Does anyone have an idea what sort of temperature the cables are exposed to in those areas of a cooker or what types of cable insulation are suitable for such a repair - should the owner wish to repair it?

  • Considering the amount of 3d printers that have set on fire because of connections to the heat bed not being up to scratch I'm going to suggest safety first, but having crimping tools be so ridiculously expensive? That's second in my eyes.

  •   comment reminds me, those micro ribbon cable connectors are extremely fragile as well. If disassembling something I get the eyeglass on them and use a scapel blade to gently see which bits are meant to move: is it a 'top lever clamp' or a 'sliding clamp'?

  • Robustness. I have a particular gripe with the DisplayPort (alll sizes) - flimsy fit and I've even had one of the large ones fall apart after two uses.