Custom and Stock Solutions
Below are some examples of how Sullins has successfully provided the perfect connector solution for our clients’ diverse and exacting applications.
Challenge: Design a connector for use in astronaut space suit battery packs. Sullins’ main challenge was that it needed to function flawlessly in zero gravity environment with potential dust and related problems.
Solution: Sullins worked closely with the customer’s charging unit designers, to create a covered edgecard connector that meets the critical specification requirements for this application.
Challenge: Design a connector system for a customer to hold a small daughter card (slightly larger than a SIMM module) in a high vibration environment.
Solution: Sullins developed a customized connector to hold this small module with a 100% confidence level of no open circuits. We met all of the customers requirements and shipped the order within three weeks.
Challenge: Reduce the cost of current customer design, where they were doing extensive secondary operations to a card edge connector in order to accommodate components on the daughter card.
Solution: Sullins developed a customized connector with all the modifications the customer was performing implemented into the mold cavity of the insulator, allowing the elimination of all secondary operations the customer was performing.
Challenge: Design a connector system that allowed for more alignment flexibility in a three connector system, allowed for the use of various board thicknesses in the same system, and allowed the use of more pin-outs within the same space for future expansion.
Solution: Sullins developed a customized connector that consisted of three double-ended, bi-level connectors mounted together via a stainless steel housing that supported the large connector assembly. The connectors accepted 0.062 PCBs on one end and 0.093 PCBs on the other end, allowing different boards to be utilized. This feature was also changeable to accommodate any combinations needed by the customer. Bi-level base design was utilized by only populating the upper half of pins. When the customer is ready to expand, the lower row will be added, basically doubling pin count without any change in overall size or shape of connector.