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60+ Years of Experience

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Short Lead Times

Month: June 2017

Multiple Connector Options for PCB Based Membrane Switches

Any industry using printed circuit board (PCB) based membrane switches needs a connector to work. Although the function is universal, the choice of connector options for PCB based membrane switches has challenges with meeting visual and operative requirements. One reason is the continuing reduction of electronic device sizes as technology advances. Our engineering designers are blending both the ability and work solutions for a variety of applications.  We focus on educating our clients about the emerging trends on how to connect the electronic membrane switches to the product’s keyboard and control schematics.

Connectors fit the contact device using wires, pins and molded housings—it is not always a simple task to select the right connector for PCB based membrane switches.  Connectors need to complement the application adding equipment durability within the limited space. Our switches include both tactile and non-tactile switches. PCB actuator switches support keyboard and touch screens. The goal is to make sure the transitory switching happens without failure.

Today, our membrane switch technology is dependable and designed to meet the changing market demands. Membrane switch designs have adapted to developments demanding components that are more durable and easily integrated using connectors.  Choosing the right connector to perform the job is our specialty.

Trends for PCB Membrane Switches

PCB based membrane allows for a better choice of connectors. The benefits of connectors are the ability to disconnect when replacing the power input, peripheral connections or PCBs. New connectors make it easier to integrate into other systems and devices. Advances in PCB applications make it more compatible with a membrane switch that has a low profile, flat surface keypad assembly.  Design updates improve the reliability, increases operating life with lower switch resistance.

If you are looking for application-specific solutions that meet product and industry standards call us. Our design team can create a connector solution that fits your control systems and product standards. Our commitment to you is rapid response keeping you active in today’s market.

As a product manufacturer, our goal is to help you keep the highest level of performance as a preferred supplier to your industry. We will configure the right solutions creating efficiency between your operational functions and industry demands.

PCB Connector Options

Technology has changed how we connect in the world of electronics. Today, flexible membrane switches connect using a flexible tail cut from the PCB material. The design allows the tail to connect to a PCB with single or multiple row connectors, designed for your equipment. You have multiple options for choosing connectors from pricing to feature functions. Our staff can help replace outdated or worn components saving time and money.

For connectors, the most economical choice of connector designed has an easy insertion. It has an interconnect capacity with a terminating feature using solder tabs that can be soldered to the PCB. This connector does not connect directly to the membrane switch—it connects to the PCB. The tail circuit inserts into the receptacle connector to make contact. Technology attaches the wire to the PCB inside of electronic devices. The ribbon cables contain the wires with bare ends placed inside of a connector. It is a single connector solution.

Traditional male, female or solder tab housings connectors need a mating half to fit the opposite wire ends. These have proven to work well in industrial environments with heavy shock or vibration. The connectors have pins crimped to the circuit, assembled into a housing design for protection and handling. These pre-terminated connector designs enable rapid installation and deployment. We can change the tail options to fit existing equipment connections or quality upgrades to the latest industry standard.

Conclusion

We integrate function controls into smaller spaces for you without the loss of quality or usability. Our systems improve equipment, component, and user operational interfaces. Even with the advancements of smaller PCBs and other components, we offer state-of-the-art devices with enhanced capabilities. Existing industry PCB based solutions can be costly or they lack the operational efficiency needed. As one of the most experienced membrane switch designers, we can configure PCB based connectors with precision. We do it by offering integrated components and assembly using our unique process ensuring compatibility.

All About Precision Solder Paste Printing

Precision solder paste printing is used to secure components onto the surfaces of printed circuit boards (PCBs). There are several steps that have to be followed to ensure the components are soldered correctly in place or problems can arise with the PCBs. This is a very delicate process that must be done with great precision to properly establish an electrical connection between the components on the PCBs. Here are the steps that have to be followed to ensure the precision solder paste printing system is done correctly.

Stencils

Stencils are needed to create a permanent diagram that will be used to apply the paste to the boards. The stencils need to be strong enough to stand up to repeated usage and are typically made out of metals like copper, nickel, stainless steel, and bronze. The thickness of the metal typically varies between 100 to 200 microns depending on the specifications of the job.

Grooves are cut into the metal by using etching, electroforming, or laser cutting methods. The electroforming and laser cutting methods have become the favored methods to create the grooves, or apertures, in the metal because the sharp and conic-shaped edge that are created along the grooves. These types of edges allow the paste to flow off of the stencil and onto the circuit boards better.

Paste

The paste is made from mixing a tin-alloy lead-based powder with a flux material to make it sticky. The stickiness is necessary to hold the components in place while the solder paste is heated and applied to the PCB. The flux is typically made from rosin-based materials from pine trees, water-soluble material from organic products and glycol, or with a mixture of resins and residues that don’t require cleaning for use in very clean manufacturing environments.

The paste has to have certain properties for it to work well. The viscosity of the paste needs to be thin enough to get pressed through the stencil with a squeegee. The viscosity of the paste also needs to be thick enough to reform once it has been applied to the surface of the PCB.

A precise amount of paste is needed to properly solder a circuit board. If too much is used, the PCB could get short-circuited, and if too little is used, the PCB will have poor electrical connections that can break.

Printing Process

A special printer is used to apply the solder paste to PCBs. A PCB board is placed into the printer and held in position using clamps.  The stencil is put over the PCB and it too is clamped into place. A squeegee is used to press the solder paste down in through the groves on the stencil and onto the surface of the PCB. When using the rosin or water-based resins, the stencil needs to be constantly wiped down to remove any residues or impurities from the environment they may collect on the stencil. The flux made from resins and residues don’t have to be constantly cleaned, but this type of flux has to be used in an environmentally controlled area.

Heating Process

Once the paste has been applied to the PCB, it is then placed into an oven. The oven will burn off the flux material so only the solder remains and the PCB is ready to be used.

Done with Precision

Every step of the process has to be done with great care. The temperature of solder, which varies depending on the process, has to remain steady. The solder, both the tin-alloy lead-based types and non-lead types, should be kept refrigerated until it is ready to be used.

The squeegees and stencils have to be well-maintained at all times. Any residue or scratches on the squeegee or stencil will usually result in the production of poor quality PCBs. Adequately controlling the squeegee speed and pressure is also essential in making sure the solder paste is placed properly onto the PCB.

Benefits of X-Ray Testing During Inspection

X-ray is a testing method in the industrial segment of the business. The benefit of using it provides a view of the internal composition of solid materials – not visible to the naked eye.  The tests are looking for hidden defects or inconsistencies of the materials used to form the product. The inconsistencies happen with new designs, a change in materials or new production processes. Finding inconsistencies is important because they affect the performance of the product. The consequences of poorly made products result in shorter life cycles, low-performance ratios, failure to meet the industrial standard and quality requirements.

The inspection regulations guiding this practice view the product using imagery. A trained and qualified inspector or a certified third-party assessor performs our in-house evaluations, documenting the findings on the test pieces. The client buying the products may specify the reports as part of the shipping documents. Some industries operate on an acceptable quality level (AQL). The AQL specifies the number of tests per product batch with an allowed percentage of failure to meet the standards. Reaching the maximum failures causes a batch rejection.

Today as a leader in electronic manufacturing, we use x-ray inspection equipment. The process offers high resolution for failure analysis throughout the production stages. Our customer is our focus ensuring our product is reliable with the highest performance once it leaves our facility. The benefits of x-ray tests for electronics leverages nondestructive testing (NDT) technology to assess operating and industry defects.

Discovery of Subsurface Defects

There are more than a dozen methods of NDT.  Each method uses a specific analysis and material composition. NDT evaluates raw materials, components or assemblies. The inspector is looking for non-conformities or differences in the material characteristics without destroying the serviceability of the part or system. The technology penetrates most materials even with varying thicknesses or multiple layers.

Radiographic testing (RT) is one NDT method using x-ray to assess solid material without damaging the product. Today, electrical and electronic assemblies use an in-house x-ray camera built into equipment.

  1. Digital radiography allows the inspector to adjust contact and zoom to an area.
  2. NDT x-ray inspections take place at a laboratory or onsite.

Technology has provided an easy method of documenting the test results, saving them to an e-file. It is an easy method for archiving and transmitting the information to engineering and production for viewing for the purpose of examination and change orders.

Acceptance or Failure Analysis

The tests determine the product’s fitness for service and reliability. Benefits of x-ray testing during inspection provide details to the fabrication process according to the product build specifications. Viewing of the product features or attributes generates approvals or rejections based on findings.

  • Internal shrinkage, cracks, weaknesses
  • Internal integrity composition
  • Weld or soldering qualities
  • Corrosion

Callouts for inspections of specific products is an industry norm. Generally, specialized industries have conformance requirements and use NDT inspections to verify the product quality prior to leaving the supplier’s facility. Sometimes the parts go back for rework and repair. There are circumstances for destroying the part due to failures identified in testing. You may lose the part, but you gain significant information on the cause of failure.

  • During production
  • Post-production
  • In-service
  • After repair

Benefits of X-Ray Testing During Inspection

Every industry has some form of testing as part of its manufacturing and quality control. The development of smaller components integrating to higher performance processes is driving the need for RT testing.  The benefits of testing are twofold; the manufacturer produces higher quality product needing fewer reworks and the customer receives consistent reliability increasing longevity.  Capturing a high-resolution image of the overlapping inner structure and welding makes it easier to identify defects and assure reliability.  

  • Crack and overlays
  • Stress measurement
  • Material testing

Conclusion

Inspections during production or post-production are cost-effective strategies and part of business risk evaluations. Effective testing provides valuable information to the next generation of design and production processes. Warranties enforce product integrity should a failure occur in the field during service. We inspect every circuit board and surface mount packing used for integrated circuits. Our investment in product integrity is helping customers to stay ahead of their competition and continue to provide quality products.

Why Your Nameplate Needs the Dome Element

Your nameplate needs the dome element to keep the image intact longer. The dome element makes it simple for customers to remember your brand and new prospects to recall the name. We share your goals and values for doing business and offer advances in manufacturing processes for nameplate longevity. While you are doing business, we are working on better designs and easier engineering processes that stand the test of time for your products.

Over the years, nameplate features have changed—one of those enhancements is the dome element combined with engineering and craftsmanship. Is it time to improve your image with a clear flexible bubble that is water, scratch and rust resistant?  Dome features include protection from chemical interactions, human interactions or environmental factors.

Dome elements are one of the latest trends—sending a message about your company and evidence to the latest technology improving your status. Customer loyalty does not just happen. It takes the best engineering to display your brand. Domes add a new dimension meeting the marketing demands to increase the appeal of your nameplate.

Engineering the Dome

Domed nameplates amplify the product’s identification for indoor and outdoor equipment, vehicles or machinery. The design is essential because we customize every nameplate to fit your equipment and space placement. The main purpose of nameplates is to make your brand noticeable.  Our engineering practices can take your nameplate from great to unbelievable using quality graphic solutions. Product tags that lasted a few years can now extend beyond five using a dome element. The dome materials and processes are part of the durability features, followed with the precision use of industry graphics.

You can choose from aluminum and steel etchings using your logo and colors. If your nameplate design has mood shadows or 3D enhancers – we are ready to exceed your design expectations. Consider using dome elements as identification tags on these products:

  • Computer equipment
  • Manufacturing equipment
  • Industrial machinery
  • Instrumentation
  • Electronic devices

The final process covers your logo nameplate with a domed industry rated urethane. The technology works on nameplate equipment controls. The coating is clear for visibility and works without interference to LED window functions.

Customizing the Designs

Whether you are manufacturing, working in medical arenas, technology or communication devices—dome elements make your company labeling and control panels more durable and better looking. If you are at a loss for ideas or at a turning point for growing your business call us. We can help improve your nameplates and expand your business brand.  We will build to spec and compliance to industry quality of materials and performance standards. Our material features for domed nameplates include:

  • Chemical resistant
  • Customized designs
  • Cost-effective
  • Weather and waterproof

Constructed to sustain changing temperatures, extreme exposure to sunlight will not yellow the dome. Domes add protection to the nameplate with durability due to the flexibility of the clear urethane covering. Our engineering teams are experts and share their knowledge on what materials work best for your nameplate, fitting function with quality.

  • Engineered durability
  • Indoor and outdoor use
  • Customized to the environment

Upgrades to a New Image

Change is a part of business and we are aware of the need for quick, exact and fast deliveries. We do our best to create your design on schedule. Remember, you are part of the sequence and your design needs to go through an evaluation to make it stand out. We pay attention to the details. We understand how you are using your dome nameplate labels. Dome nameplates have a standard thickness, but you can customize—we will remind you about the limitations to keep the quality of your dome nameplate intact. The change in thickness needs to accommodate the shape of the nameplate and the location for visibility and durability. The final process ensures the edges are smooth and sealed to avoid damage.

Conclusion

We meet the growing demand for dome elements. We are a specialized manufacturer and quality supplier for product labels and graphic overlays. Our standards show our commitment to engineering your nameplates to weather time until they need updating using the next generation of technology. Send us your challenge and allow our staff to add the dome elements to your nameplates.