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handylink? application specification revision: ecr/ecn information: sheet no. ec no: ucp2008-0962 b date: 2007/10/30 title: application specification handylink?i/o connector system 3 of 27 document number: created / revised by: checked by: approved by: sd - 44828 - 001 m. simmel / d. morgan b. barker s. miller template filename: product_spec[size_a](v.1).doc handylink? i/o connectors 44828 smt receptacle 45560 smt cradle connector connector 45339 and 45593 plug connector modules
handylink? application specification revision: ecr/ecn information: sheet no. ec no: ucp2008-0962 b date: 2007/10/30 title: application specification handylink?i/o connector system 4 of 27 document number: created / revised by: checked by: approved by: sd - 44828 - 001 m. simmel / d. morgan b. barker s. miller template filename: product_spec[size_a](v.1).doc table of contents section page section page 1.0 scope 3 2.0 product description 3 3.0 applicable documents and specifications 3 4.0 mating and un-mating of connectors 4.1 recommendations for mating and un-mating 4 4.2 mating alignment tolerances 4 5.0 soldering process recommendations 5.1 44828 smt receptacle connector 6 5.1.1 pcb layout 5.1.2 solder paste stencil layout 5.1.3 reflow profile 5.1.4 inspection 5.2 45560 smt cradle connector 6 5.2.1 pcb layout 5.2.2 solder paste stencil layout 5.2.3 reflow profile 5.2.4 inspection 5.3 45339 plug module for wire termination 7 5.3.1 applicable wire sizes 5.3.2 wire preparation 5.3.3 inspection 5.4 45593 plug module for pcb termination 7 5.4.1 pcb layout 5.4.2 inspection 6.0 mechanical design recommendations 6.1 mechanical fasteners and support 8 6.1.1 receptacle connector 6.1.2 plug connector modules 6.1.3 cradle connector 6.2 ingress protection 10 6.3 plug cable over-molding 11 6.3.1 wire soldering 6.3.2 encapsulation 6.3.3 strain relief 6.3.4 final over-molding 6.4 design best practices 14 6.4.1 plug over-mold designs 6.4.2 cradle designs 7.0 electrical recommendations 7.1 power considerations 21 7.2 high speed signal transmission 21
handylink? application specification revision: ecr/ecn information: sheet no. ec no: ucp2008-0962 b date: 2007/10/30 title: application specification handylink?i/o connector system 5 of 27 document number: created / revised by: checked by: approved by: sd - 44828 - 001 m. simmel / d. morgan b. barker s. miller template filename: product_spec[size_a](v.1).doc 1.0 scope this specification addresses the manufacturing tech niques and end-usage considerations for molexs 0.8 mm pitch handylink? i/o connectors. the common contact interface used in t his family of connectors consists of a flat pad mat ed to a radiussed edge on a compression spring blade. the flat pad is enclosed by plastic in an over-molded receptacle housing wh ich provides a sealed ineterface to facilitate ingress protection. the c ompression spring blades are extremely durable and are capable of sustaining over 20,000 mating cycles. two passive latches counte ract the compression springs to keep the connector pairs mated but enable simple disconnection by the end-user. the customer is encouraged to contact molex with an y questions regarding the application of this produ ct. 2.0 product description 2.1 product names and part numbers smt receptacle connectors series : 44828 smt cradle connectors series 45560 (perpendicular and parallel mating) plug connector modules series 45339 (wire termination) series 45593 (pcb termination) 2.2 dimensions, materials, platings, and markings (see applicable sales drawings for information) 3.0 applicable documents and specifications product specification: ps-44828-001; sales drawing s: sd-44828-162, sd-45560-160, sd-45560-161 , sd-45339-160, sd-45593-160
handylink? application specification revision: ecr/ecn information: sheet no. ec no: ucp2008-0962 b date: 2007/10/30 title: application specification handylink?i/o connector system 6 of 27 document number: created / revised by: checked by: approved by: sd - 44828 - 001 m. simmel / d. morgan b. barker s. miller template filename: product_spec[size_a](v.1).doc 4.0 mating and un-mating of connectors this section describes the preferred methods for ma ting and un-mating the handylink? connectors. 4.1 recommendations for mating and un-mating this connector system utilizes a passive latching feature. there is no button to press to latch or unlatch. to latch, simply push the plug into the receptacle (the connectors are polari zed to discourage improper mating). to unlatch, si mply grip the plug body firmly and pull it straight out of the receptacle. 4.2 mating alignment tolerances 4.2.a 44828 receptacle to 45339 or 45593 plug conne ctors the handylink? plug and receptacle have been appropr iately designed and toleranced to be mated and unma ted by hand. the connectors alignment features are manufactured wit h clearances to allow axial mating mis-alignment, a s illustrated in the figure 1, below: figure 1. receptacle to plug connector axial alignment (units: mm)
handylink? application specification revision: ecr/ecn information: sheet no. ec no: ucp2008-0962 b date: 2007/10/30 title: application specification handylink?i/o connector system 7 of 27 document number: created / revised by: checked by: approved by: sd - 44828 - 001 m. simmel / d. morgan b. barker s. miller template filename: product_spec[size_a](v.1).doc 4.2 mating alignment tolerances (continued) 4.2.b 44828 receptacle to 45560 cradle connectors the handylink? receptacle and cradle connectors ali gnment features are manufactured with clearances to allow some axial mating mis-alignment as illustrated in the figure 2, below : figure 2. receptacle to cradle connector axial alignment (units: mm) note: mating misalignment may significantly influe nce the long-term durability of the connectors. th e risk of housing wear diminishes with increasing the accuracy of connector alignment .
handylink? application specification revision: ecr/ecn information: sheet no. ec no: ucp2008-0962 b date: 2007/10/30 title: application specification handylink?i/o connector system 8 of 27 document number: created / revised by: checked by: approved by: sd - 44828 - 001 m. simmel / d. morgan b. barker s. miller template filename: product_spec[size_a](v.1).doc 4.3 clearances between mated parts the handylink connectors are designed such that th e corresponding front faces fully engage and then spring back 0.20mm to the final mated condition. this over-travel clearance assures that the components of the passive latchi ng system engage. please see section 6.4 design best practices for further detai led information. 5.0 soldering process recommendations 5.1 44828 smt receptacle connector 5.1.1 pcb layout see the applicable sales drawing for an illustratio n of the recommended pcb layout. contact molex if further assistance is required. 5.1.2 solder paste stencil layout see sales drawing for solderable surfaces. contact molex if further assistance is required. 5.1.3 reflow profile while the production solder reflow profile is typic ally established by the customer, based on their sp ecific application, generic reflow profiles can be found in product specification ps-4 4828-001. the profiles are provided for reference purposes only. 5.1.4 inspection solder joints should be inspected using established conventional methods. 5.2 45560 smt cradle connector 5.2.1 pcb layout see the applicable sales drawings for illustrations of the recommended pcb pad layouts. contact molex if further assistance is required. 5.2.2 solder paste stencil layout see sales drawing for recommended pcb pad layout an d solder paste thickness.
handylink? application specification revision: ecr/ecn information: sheet no. ec no: ucp2008-0962 b date: 2007/10/30 title: application specification handylink?i/o connector system 9 of 27 document number: created / revised by: checked by: approved by: sd - 44828 - 001 m. simmel / d. morgan b. barker s. miller template filename: product_spec[size_a](v.1).doc 5.2.3 reflow profile while the production solder reflow profile is typic ally established by the customer, based on their sp ecific application, generic reflow profiles can be found in product specification ps-44828-001. the profiles a re provided for reference purposes only. 5.2.4 inspection solder joints should be inspected using established conventional methods. 5.3 45339 plug module for wire termination 5.3.1 applicable wire sizes copper conductor size: 22 to 34 awg (stranded wires are recommended for flexibility) may be used, however, 22 to 28 awg conductors are necessary to t ransmit 1.5 amperes dc continuously. maximum insulation diameter: 1.6mm note: small conductor sizes are suitable for the t ransmission of digital signals, and may improve wir e bundle flexibility and harness workability. 5.3.2 wire preparation strip length: 2.0 ~ 2.5mm pre-tinning is recommended. 5.3.3 inspection solder joints should be inspected using established conventional methods . 5.4 45593 plug module for pcb termination 5.4.1 pcb layout see the applicable sales drawing for an illustratio n of the recommended pcb hole layout. 5.4.2 inspection solder joints should be inspected using established conventional methods .
handylink? application specification revision: ecr/ecn information: sheet no. ec no: ucp2008-0962 b date: 2007/10/30 title: application specification handylink?i/o connector system 10 of 27 document number: created / revised by: checked by: approved by: sd - 44828 - 001 m. simmel / d. morgan b. barker s. miller template filename: product_spec[size_a](v.1).doc 6.0 mechanical mounting recommendations 6.1 mechanical fasteners and support 6.1.1 receptacle connector molex recommends that the receptacle connector be m ounted within the end-application enclosure such th at it is recessed by 1.6 to 2.4mm from the outermost faces and with a 0.10mm ma ximum clearance with the casing inner walls. such a recess provides multiple advantages in terms of protecting the contact surfa ces from accidental impact with foreign objects, pr oviding mechanical support when the mating plug connector assembly is torqued by ab usive handling, and helps to reduce direct contact with hand oils or other contamination. see figures 3a and 3b, below, for r ecommendations on recess dimensions. figure 3a. receptacle connector recess when mating with the plug only (units: mm)
handylink? application specification revision: ecr/ecn information: sheet no. ec no: ucp2008-0962 b date: 2007/10/30 title: application specification handylink?i/o connector system 11 of 27 document number: created / revised by: checked by: approved by: sd - 44828 - 001 m. simmel / d. morgan b. barker s. miller template filename: product_spec[size_a](v.1).doc figure 3b. receptacle connector recess when mating with the plug or cradle connectors (units: mm) wherever possible, the 0.10 maximum clearance condi tion with the receptacle should be minimized by uti lizing a clam-shell style package design. 6.1.2 plug connector module the plug connector module is intended to be used as a part of a assembly using either direct wire sold ering ( 45339 ) or using an intermediary pcb ( 45593 ). overmolding and/or clam shell style covers must be used to protect the wire connections and the appropriate service loops and wire strain reliefs m ust be incorporated in a cable assembly to prevent damage during use. please refer to section 6.3 for further details about the over-m olding process. if the connector module is used as a stand-alone co mponent on a pcb, the mating interface must be adeq uately supported. please refer to section 6.4.2 for further details concerni ng cradle design recommendations. 6.1.3 cradle connector the cradle connector is designed to be fastened to the pcb with screws. see sales drawings for recomm ended screw size and positions. please refer to section 6.4.2 for furth er details concerning cradle design recommendations .
handylink? application specification revision: ecr/ecn information: sheet no. ec no: ucp2008-0962 b date: 2007/10/30 title: application specification handylink?i/o connector system 12 of 27 document number: created / revised by: checked by: approved by: sd - 44828 - 001 m. simmel / d. morgan b. barker s. miller template filename: product_spec[size_a](v.1).doc 6.2 ingress protection ingress protection, as described by iec 60529, is a function of the customers enclosure. the handyli nk? receptacle connector has been designed to facilitate enclosure design when i ngress protection is required. the interfaces betw een the metal and plastic components of the connector are sealed to discourag e intrusion of dust and liquid through the connecto r into the enclosure. the customer is expected to design an appropriate seal around the periphery of the connector to adequately seal the finished enclosure. contact molex for additional information. gaskets may be applied to the top and sides, or front surfaces. the bottom surface, once soldered, forms a continuo us seal with the pcb figure 4. sealing to achieve ingress protection with the re ceptacle connector
handylink? application specification revision: ecr/ecn information: sheet no. ec no: ucp2008-0962 b date: 2007/10/30 title: application specification handylink?i/o connector system 13 of 27 document number: created / revised by: checked by: approved by: sd - 44828 - 001 m. simmel / d. morgan b. barker s. miller template filename: product_spec[size_a](v.1).doc 6.3 plug cable over-molding 6.3.1 wire soldering this section provides an outline of the recommended plug cable over-molding practices for the 45339 and 45593 plug connector modules. th e 45339 connector (a 16-circuit wire termination ve rsion) is shown, below, prior to soldering. please note the following features: latch soldertails (2 places) wire soldertails (2 rows) cavities under the latches (2 places) figure 5. soldertail side of the plug connector pre-tinned wires should be terminated to the approp riate solder tails working in sequence and one row at a time, taking care that the insulation does not become exposed more than 1m m from the end of the terminals. the completed ass embly after soldering of the wires is shown below. dressing of the wires sh ould be avoided until after the soldering and encap sulation processes are complete.
handylink? application specification revision: ecr/ecn information: sheet no. ec no: ucp2008-0962 b date: 2007/10/30 title: application specification handylink?i/o connector system 14 of 27 document number: created / revised by: checked by: approved by: sd - 44828 - 001 m. simmel / d. morgan b. barker s. miller template filename: product_spec[size_a](v.1).doc figure 6. plug soldering set-up note : the wire bundle must be properly supported or clamp ed as shown, during soldering and handling, to avoid disl odging terminals or latches from the housing prior to encapsulation, ap plication of a strain relief, and the final over-mold.
handylink? application specification revision: ecr/ecn information: sheet no. ec no: ucp2008-0962 b date: 2007/10/30 title: application specification handylink?i/o connector system 15 of 27 document number: created / revised by: checked by: approved by: sd - 44828 - 001 m. simmel / d. morgan b. barker s. miller template filename: product_spec[size_a](v.1).doc 6.3.2 encapsulation the next step after soldering is to pre-seal or enc apsulate the back end of the connector and hold the wires in place using a silicone sealant or a low-pressure macro-melt polyamide adhe sive molding. the sealant will prevent accidental shorting between adjacent terminals and discourage intrusion of over-mold res in into the terminal and latch cavities. an illust ration of the pre-seal coverage is shown below. care must be taken to ensure that no encapsulant enters the terminal or latch cavities. figure 7. encapsulated plug connector an alternate method is to combine one or more molde d covers to block entire sections where void circ uits are present, then use a pre-seal or encapsulant to hold the wires separate. this is illustrated below. figure 8. covered and encapsulated plug connector note: the sealant or cover should enclose the cavi ties under the latches, whether or not wires are so ldered to the latches. omission of this step would allow the final over-mold resin to extrude into cavities in the housing that could disable latch and terminal function.
handylink? application specification revision: ecr/ecn information: sheet no. ec no: ucp2008-0962 b date: 2007/10/30 title: application specification handylink?i/o connector system 16 of 27 document number: created / revised by: checked by: approved by: sd - 44828 - 001 m. simmel / d. morgan b. barker s. miller template filename: product_spec[size_a](v.1).doc 6.3.3 strain relief molex strongly recommends the use of a crimp barrel or ferrule over the wire bundle (including ground or drain wire) that also captures the cable jacket and tension member, if used. thi s will uniformly distribute mechanical loads through the wire bundle and provid e mechanical support to the cable jacket and tensio n member. figure 9. crimp barrel installed 6.3.4 final over-molding the final pvc over-mold may be injection-molded to completely cover the prepared cable assembly to pro vide an esthetically pleasing finished product. please see section 6.4. 1 for a discussion of design best practices for the over-mold. figure 10. finished over-mold (shown transparent)
handylink? application specification revision: ecr/ecn information: sheet no. ec no: ucp2008-0962 b date: 2007/10/30 title: application specification handylink?i/o connector system 17 of 27 document number: created / revised by: checked by: approved by: sd - 44828 - 001 m. simmel / d. morgan b. barker s. miller template filename: product_spec[size_a](v.1).doc 6.4 design best practices the information provided so far in this document ha s been related to the basic usage conditions of the handylink? connectors. the sections that follow contain important information and guidelines for design that apply to specific ap plications or industrial design constraints for the end-product accessories. in al l cases, molex advises that prototype assemblies be used as early in the design and development cycle as possible to simulate and asses s true usage conditions in the actual end-products. please contact molex for technical assistance with design feasibility studies or design reviews. 6.4.0 mating over-travel clearance the handylink connectors are designed such that the corresponding front faces fully engage and then spring back 0.20mm to the final mated condition. this over-travel clearance assures that the components of the passive latchi ng system engage, as illustrated in figure 11. this clearance must be accommodated in all device and accessory designs top assure proper function. plug connector 0.20mm over-travel clearance between connectors when mated receptacle connector hook la tch
handylink? application specification revision: ecr/ecn information: sheet no. ec no: ucp2008-0962 b date: 2007/10/30 title: application specification handylink?i/o connector system 18 of 27 document number: created / revised by: checked by: approved by: sd - 44828 - 001 m. simmel / d. morgan b. barker s. miller template filename: product_spec[size_a](v.1).doc 6.4.1 plug over-mold designs supplemental guide features to align the connectors during mating or un-mating are strongly recommende d if any of the following conditions are present: o a great deal of curvature in the end product (such as that illustrated, below); o the accessory cable is stiff or bent abruptly; o the mass of the end-product itself is greater than 1000grams and is likely to experience more than 1g of acceleration during use or under vibration; o the cable connection and disconnection cycles are numerous (more than 5000 cycles); o there is significant risk of the end users pulling at connections in off-axis directions. figure 12. example of an application with a great degree of curvature near the connector interface. supplemental guide features may be incorporated int o or complement the over-mold design as illustrated in figures 12 and 13:
handylink? application specification revision: ecr/ecn information: sheet no. ec no: ucp2008-0962 b date: 2007/10/30 title: application specification handylink?i/o connector system 19 of 27 document number: created / revised by: checked by: approved by: sd - 44828 - 001 m. simmel / d. morgan b. barker s. miller template filename: product_spec[size_a](v.1).doc o contouring with a lip to provide mechanical support for torque out of the axial plane of the connectors, the over-mold must be designed to mimic the outer surfaces of the end product and include a lip such as illustrated below. note: the axial cleara nce condition between the connectors noted in section 4.2 must be maintained. figure 13. example of an over-mold with contouring and a lip this type of design will provide support for the en d-user to hold the product by the connector or wher e a heavy or stiff accessory cable is used. over-molded lip off-axis torque directions surfaces are contoured to mimic the end product
handylink? application specification revision: ecr/ecn information: sheet no. ec no: ucp2008-0962 b date: 2007/10/30 title: application specification handylink?i/o connector system 20 of 27 document number: created / revised by: checked by: approved by: sd - 44828 - 001 m. simmel / d. morgan b. barker s. miller template filename: product_spec[size_a](v.1).doc o supplemental latching and alignment posts where the mass of the end product is greater than 1 000 grams and is subject to sudden accelerations or strong vibrations during use, a cup-style receptacle needs to be considered to adequately protect the connection interface. th e cup-style receptacle should incorporate separate external latching features and supplemental alignment posts similar to those illu strated below. note: the cup- style receptacles dimensions must restrict angular misalignment, when mated, to within the limits spe cified in section 4.2. figure 14. use of a cup-style receptacle for added support a nd alignment external latching feature (each side) supplemental alignment posts cup-style receptacle (separate molded part) guid e ribs (each side)
handylink? application specification revision: ecr/ecn information: sheet no. ec no: ucp2008-0962 b date: 2007/10/30 title: application specification handylink?i/o connector system 21 of 27 document number: created / revised by: checked by: approved by: sd - 44828 - 001 m. simmel / d. morgan b. barker s. miller template filename: product_spec[size_a](v.1).doc supplemental alignment posts must be longer than th e protrusion of the plug connector posts from the b ase surface of the cup-style receptacle. further, the alignment posts centerli nes must lie in the same plane as the centerlines o f the plug connector posts to provide the greatest benefits. guide ribs are nece ssary to prevent front-to back rocking motion as th e device is loaded into the cup- style receptacle. note: the fastening of the cup-style receptacle to the over-molded plug must be kept tight to avoid mi salignment. if this is not achieved, excessive wear between the connector hous ings and/or electrical discontinuities may occur.
handylink? application specification revision: ecr/ecn information: sheet no. ec no: ucp2008-0962 b date: 2007/10/30 title: application specification handylink?i/o connector system 22 of 27 document number: created / revised by: checked by: approved by: sd - 44828 - 001 m. simmel / d. morgan b. barker s. miller template filename: product_spec[size_a](v.1).doc 6.4.2 cradle designs o cup style the cup or holster style of cradle provides the gre atest degree of alignment between mating connectors . where the end product mass is greater than 1000 grams the use of suppleme ntal alignment posts is recommended. the alignment posts effective length (not including any lead-in taper) must be longer than th e protrusion of the connector posts from the base s urface of the cup-style receptacle. further, the alignment posts centerlines must lie in the same plane as the centerlines of the plug co nnector posts to provide the greatest benefits. guide ribs are necessary on each side to limit front-to back rocking motion as the device i s loaded into the cup-style cradle. figure 15. cup-style cradle features note: for details about mounting the connectors to the pcb and the use of fasteners, please refer to the applicable sales dra wings. supplemental alignment posts guide rails (each side)
handylink? application specification revision: ecr/ecn information: sheet no. ec no: ucp2008-0962 b date: 2007/10/30 title: application specification handylink?i/o connector system 23 of 27 document number: created / revised by: checked by: approved by: sd - 44828 - 001 m. simmel / d. morgan b. barker s. miller template filename: product_spec[size_a](v.1).doc figures 16 and 17 show orthogonal views of showing differences in the position and size of the opening s in the cradle casing, and the pcb location for the 45560 and 45593 connectors . figure 18 shows a chamfer detail applicable to 4 5593. figure 16. cradle detail (45560) figure 17. cradle detail (45593) figure 18. detail from fig. 17. (units: mm) (units: mm) (units: mm)
handylink? application specification revision: ecr/ecn information: sheet no. ec no: ucp2008-0962 b date: 2007/10/30 title: application specification handylink?i/o connector system 24 of 27 document number: created / revised by: checked by: approved by: sd - 44828 - 001 m. simmel / d. morgan b. barker s. miller template filename: product_spec[size_a](v.1).doc o shelf style to achieve a rocking disconnection for the end pr oduct from the cradle, a shelf style cradle design may be used under the following conditions: no supplemental guide posts may be used; the end product may not have more than 1000 grams mass; side-to-side motion must be limited using end-wall s or a guide rail; the vibration conditions of the end application mu st be limited. figure 19. shelf-style cradle features note: for details about mounting the connectors to the pcb and the use of fasteners, please refer to the applicable sales dra wings. connect direction disconnect rocking direction shelf (bearing surface)
handylink? application specification revision: ecr/ecn information: sheet no. ec no: ucp2008-0962 b date: 2007/10/30 title: application specification handylink?i/o connector system 25 of 27 document number: created / revised by: checked by: approved by: sd - 44828 - 001 m. simmel / d. morgan b. barker s. miller template filename: product_spec[size_a](v.1).doc in addition to the differences in the position and size of the openings in the cradle casing, the pcb location for the 45560 and 45593 connectors, and the chamfer detail applicable to 45 593 that is shown in figures 16 thru 18. figures 2 0 through 22 illustrate details necessary to achieve a good rocking design. figure 20. front view of shelf-style cradle figure 21. section view of shelf-style cradle (units: mm) back support (required)
handylink? application specification revision: ecr/ecn information: sheet no. ec no: ucp2008-0962 b date: 2007/10/30 title: application specification handylink?i/o connector system 26 of 27 document number: created / revised by: checked by: approved by: sd - 44828 - 001 m. simmel / d. morgan b. barker s. miller template filename: product_spec[size_a](v.1).doc figure 22. connector orientation rocking direction note: orientation of the receptacle connector and the plug or cradle connector must correspond to tha t shown for good operation of a rocking design.
handylink? application specification revision: ecr/ecn information: sheet no. ec no: ucp2008-0962 b date: 2007/10/30 title: application specification handylink?i/o connector system 27 of 27 document number: created / revised by: checked by: approved by: sd - 44828 - 001 m. simmel / d. morgan b. barker s. miller template filename: product_spec[size_a](v.1).doc 7.0 electrical recommendations 7.1 power considerations please see the product specification, ps-44828-001, for the nominal electrical specifications. for ap plications where the sustained electrical power usage requirements exceed the limi ts stated in the product specification, the use of multiple circuits is suggested. when the end-application is likely to encounter sal t spray conditions, potential differences exceeding 4vdc should be separated by more than one terminal position (i.e. 1.6mm or more ) to avoid galvanic corrosion between circuits. 7.2 high speed signal transmission testing has shown that under the usb 2.0 specificat ion environment for connector components and cable assemblies (200 and 500 picosecond rise times), the handylink connector s perform within specification for both differentia l and common-mode impedance. full compliance testing on finished cable assemblie s will have to be undertaken to verify the performa nce level of the finished product. contact molex for further assistance regarding high speed signal transmission applications.

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