Current obviously only flows when a circuit is closed, but there are many options on how to get there. For example, how do you connect appliance sockets in a power distribution unit in the most efficient way? Here is an overview of possible connection technologies for these kinds of applications.
A power distribution unit has the purpose of supplying power to a large number of devices. It is subject to moderate mechanical shocks due to the plugging in and out of device connection cables. In most cases, it performs its duties in a thermally stable, ventilated room. The connectors of appliance couplers refer to the contacts on the inside of the connector. One can differentiate between the following connection variants. Let's take a closer look at the advantages and disadvantages of each one.
Manual soldering connection
Soldering is the joining of metal parts by a metal alloy (solder) under the impact of heat. The melting temperature of the solder is below the other metals to be joined. At the right temperature, the hot solder flows between the two metal parts. Under appropriate conditions, a strong, tight, corrosion-resistant, current- and heat-conducting joint is formed between the solder and the metals. In general, a distinction is made between soft and hard soldering. Soft solders have a melting point below 450 °C. Brazing solders have a melting point between 450 °C and 1100 °C. In electronics, soft soldering is standard.
- Advantages: If the soldering is done by a professional and all contact points are free of oils, oxidation or other contaminants, an excellent connection is formed.
- Disadvantages: Manual soldering requires a comparatively high effort. The cable or stranded wire must be stripped, and the work requires attention to detail
Printed circuit board connection
The printed circuit board connection consists of a coated metal contact which is soldered to the contact point of a conductor track on a printed circuit board. Basically, a distinction is made between through-hole technology (THT) and surface mounting technology (SMT). In the case of a power distribution unit, THT is the standard case.
- Advantages: No cables are involved. Stripping is not necessary. If the soldering is also carried out by a professional and all contact points are clean, an excellent connection is formed.
- Disadvantages: The mechanical load on the socket always causes a load on the PCB as well since these are rigidly connected. The soldering itself is again almost always done manually, which requires time and care.
IDC
An insulation displacement contact (IDC) is an electrical connector designed to be connected to the conductor of a SCHURTER 6610 device socket outlet with IDC terminals for snap-in mounting. 2 White Paper Connectors insulate the cable via a mechanical connection process. In this process, a sharpened blade on the contact surfaces of the cable is pressed through the cable insulation. When professionally handled, this connector blade welds to the conductor and makes a reliable, gas-tight connection.
Multiple cables can be gas-tightly pressed into the 6610 in one step with the cover.
- Advantages: Enormously efficient process that does not require stripping or soldering. The connection withstands mechanical stress well. Oxidation is also hardly an issue if done properly. Very cost-effective process. Can't be done any faster.
- Disadvantages: Cable diameters must match the insulation displacement connectors and may be rather stiff and straight. Thin strands are therefore less suitable. Pressing in the cables by means of special tools or the cover must be done with care and precision.
Example of a SCHURTER filter with preassembled strands and potting compound.
Summary
For smaller quantities, manual soldering still has its justification. If done professionally, you get an excellent connection, electrically as well as mechanically. For larger quantities - and when it really must go quickly - the IDC connection can hardly be surpassed. Here too, care is required when pressing in the non-stripped cables. However, the customized version is undoubtedly the ultimate solution. For high-end applications (e.g., medical technology) it is the ideal way to go. SCHURTER has been offering this service for several years and plans to expand it massively.
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