Analysis and Research on Failure Mechanism of Electrical Connector Burning Failure Mode

There are many failures in the use of electrical connectors, such as increased contact resistance, intermittent open circuit, reduced insulation resistance, electrical burnout, etc. The most common failure manifestation is burnout. In order to help the manufacturers improve the quality level and the inherent reliability of the electrical connector; and assist the users reasonable applicate the electrical connector, so can improve the application reliability of the electrical connector, thereby reducing the risk of burnout in use, it is necessary to recognize the possible failure mechanism and root cause of the electrical connector burnout. The author analyzed the rules of many failure cases for electrical connector burnout, summarized these cases, and analyzes the possible mechanisms and root causes of burnout failure modes of electrical connectors. Finally, a large number of cases supported the analysis of this article, which can be used as a reference for engineers and technicians engaged in failure analysis and product improvement. The failure mechanisms and related causes of electrical connector burnout are quite complicated, such as poor crimping, excessive impedance of the contact point, insufficient dielectric strength of the insulating plastic, surface contamination of the insulating plastic, excessive carrying current, and excessive use temperature.