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handylink? application specification revision: ecr/ecn information: sheet no. ec no: ucp2009-1982 b date: 2009/02/09 title: application specification handylink?i/o connector system 3 of 27 document number: created / revised by: checked by: approved by: sd - 45560 - 001 m. simmel/d. morgan m. ibarra s. miller template filename: product_spec[size_a](v.1).doc 3 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: ucp2009-1982 b date: 2009/02/09 title: application specification handylink?i/o connector system 4 of 27 document number: created / revised by: checked by: approved by: sd - 45560 - 001 m. simmel/d. morgan m. ibarra s. miller template filename: product_spec[size_a](v.1).doc 4 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: ucp2009-1982 b date: 2009/02/09 title: application specification handylink?i/o connector system 5 of 27 document number: created / revised by: checked by: approved by: sd - 45560 - 001 m. simmel/d. morgan m. ibarra s. miller template filename: product_spec[size_a](v.1).doc 5 1.0 scope this specification addresses the manufacturing techniques and end-usage considerations for molexs 0.8mm pitch handy link? i/o connectors. the common contact interface used in this f amily of connectors consists of a flat pad mated to a ra diussed edge on a compression spring blade. the flat pad is enclosed by pl astic in an over-molded receptacle housing which provides a sealed ineterface to facilitate ingress protection. the compressi on spring blades are extremely durable and are capable of sustaining over 20,000 mating cycles. two passive latches counteract the compression springs to keep the connector pairs mated bu t enable simple disconnection by the end-user. the customer is encouraged to contact molex with any ques tions regarding the application of this product. 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 draw ing 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: ucp2009-1982 b date: 2009/02/09 title: application specification handylink?i/o connector system 6 of 27 document number: created / revised by: checked by: approved by: sd - 45560 - 001 m. simmel/d. morgan m. ibarra s. miller template filename: product_spec[size_a](v.1).doc 6 4.0 mating and un-mating of connectors this section describes the preferred methods for mating 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 polarized to discourage improper mating). to unlatch, simply gri p 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 appropria tely designed and toleranced to be mated and unmated by hand. the connectors alignment features are manufactured with cl earances to allow axial mating mis-alignment, as illustr ated 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: ucp2009-1982 b date: 2009/02/09 title: application specification handylink?i/o connector system 7 of 27 document number: created / revised by: checked by: approved by: sd - 45560 - 001 m. simmel/d. morgan m. ibarra s. miller template filename: product_spec[size_a](v.1).doc 7 4.2 mating alignment tolerances (continued) 4.2.b 44828 receptacle to 45560 cradle connectors the handylink? receptacle and cradle connectors alignme nt features are manufactured with clearances to allow som e 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 influence the long-term durability of the connectors. the risk of housing wear diminishes with increasing the accuracy of connector alignment.
handylink? application specification revision: ecr/ecn information: sheet no. ec no: ucp2009-1982 b date: 2009/02/09 title: application specification handylink?i/o connector system 8 of 27 document number: created / revised by: checked by: approved by: sd - 45560 - 001 m. simmel/d. morgan m. ibarra s. miller template filename: product_spec[size_a](v.1).doc 8 4.3 clearances between mated parts the handylink connectors are designed such that the corr esponding front faces fully engage and then spring b ack 0.20mm to the final mated condition. this over-travel clearance assu res that the components of the passive latching system eng age. please see section 6.4 design best practices for further detailed information. 5.0 soldering process recommendations 5.1 44828 smt receptacle connector 5.1.1 pcb layout see the applicable sales drawing for an illustration o f the recommended pcb layout. contact molex if furth er assistance is required. 5.1.2 solder paste stencil layout see sales drawing for solderable surfaces. contact mole x if further assistance is required. 5.1.3 reflow profile while the production solder reflow profile is typicall y established by the customer, based on their specific app lication, generic reflow profiles can be found in product specification ps-44828- 001. the profiles are provided for reference purposes only. 5.1.4 inspection solder joints should be inspected using established conven tional methods. 5.2 45560 smt cradle connector 5.2.1 pcb layout see the applicable sales drawings for illustrations of t he recommended pcb pad layouts. contact molex if fur ther assistance is required. 5.2.2 solder paste stencil layout see sales drawing for recommended pcb pad layout and solder paste thickness.
handylink? application specification revision: ecr/ecn information: sheet no. ec no: ucp2009-1982 b date: 2009/02/09 title: application specification handylink?i/o connector system 9 of 27 document number: created / revised by: checked by: approved by: sd - 45560 - 001 m. simmel/d. morgan m. ibarra s. miller template filename: product_spec[size_a](v.1).doc 9 5.2.3 reflow profile while the production solder reflow profile is typicall y established by the customer, based on their specific app lication, generic reflow profiles can be found in product specification ps-44828-001. the profiles are p rovided for reference purposes only. 5.2.4 inspection solder joints should be inspected using established conven tional methods. 5.3 45339 plug module for wire termination 5.3.1 applicable wire sizes copper conductor size: 22 to 34 awg (stranded wires ar e recommended for flexibility) may be used, however, 22 to 28 awg conductors are necessary to transmi t 1.5 amperes dc continuously. maximum insulation diameter: 1.6mm note: small conductor sizes are suitable for the transm ission of digital signals, and may improve wire 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 conven tional methods . 5.4 45593 plug module for pcb termination 5.4.1 pcb layout see the applicable sales drawing for an illustration o f the recommended pcb hole layout. 5.4.2 inspection solder joints should be inspected using established conven tional methods .
handylink? application specification revision: ecr/ecn information: sheet no. ec no: ucp2009-1982 b date: 2009/02/09 title: application specification handylink?i/o connector system 10 of 27 document number: created / revised by: checked by: approved by: sd - 45560 - 001 m. simmel/d. morgan m. ibarra s. miller template filename: product_spec[size_a](v.1).doc 10 6.0 mechanical mounting recommendations 6.1 mechanical fasteners and support 6.1.1 receptacle connector molex recommends that the receptacle connector be mount ed within the end-application enclosure such that it is recessed by 1.6 to 2.4mm from the outermost faces and with a 0.10mm maxi mum clearance with the casing inner walls. such a recess p rovides multiple advantages in terms of protecting the contact surfaces fr om accidental impact with foreign objects, providing mech anical support when the mating plug connector assembly is torqued by abusive handling, and helps to reduce direct contact with hand oils or other contamination. see figures 3a and 3b, below, for reco mmendations on recess dimensions. figure 3a. receptacle connector recess when mating with the plug o nly (units: mm)
handylink? application specification revision: ecr/ecn information: sheet no. ec no: ucp2009-1982 b date: 2009/02/09 title: application specification handylink?i/o connector system 11 of 27 document number: created / revised by: checked by: approved by: sd - 45560 - 001 m. simmel/d. morgan m. ibarra s. miller template filename: product_spec[size_a](v.1).doc 11 figure 3b. receptacle connector recess when mating with the plug or cradle connectors (units: mm) wherever possible, the 0.10 maximum clearance condition with the receptacle should be minimized by utilizing a clam-shell style package design. 6.1.2 plug connector module the plug connector module is intended to be used as a p art of a assembly using either direct wire soldering ( 45339 ) or using an intermediary pcb ( 45593 ). overmolding and/or clam shell style covers must be u sed to protect the wire connections and the appropriate service loops and wire strain reliefs must be incorporated in a cable assembly to prevent damage dur ing use. please refer to section 6.3 for further details about the over-mol ding process. if the connector module is used as a stand-alone componen t on a pcb, the mating interface must be adequately su pported. please refer to section 6.4.2 for further details concerning cr adle design recommendations. 6.1.3 cradle connector the cradle connector is designed to be fastened to the p cb with screws. see sales drawings for recommended screw size and positions. please refer to section 6.4.2 for further de tails concerning cradle design recommendations.
handylink? application specification revision: ecr/ecn information: sheet no. ec no: ucp2009-1982 b date: 2009/02/09 title: application specification handylink?i/o connector system 12 of 27 document number: created / revised by: checked by: approved by: sd - 45560 - 001 m. simmel/d. morgan m. ibarra s. miller template filename: product_spec[size_a](v.1).doc 12 6.2 ingress protection ingress protection, as described by iec 60529, is a func tion of the customers enclosure. the handylink? receptacl e connector has been designed to facilitate enclosure design when ingress protection is required. the interfaces between the m etal and plastic components of the connector are sealed to discourage intru sion of dust and liquid through the connector 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 continuous seal with the pcb figure 4. sealing to achieve ingress protection with the recept acle connector
handylink? application specification revision: ecr/ecn information: sheet no. ec no: ucp2009-1982 b date: 2009/02/09 title: application specification handylink?i/o connector system 13 of 27 document number: created / revised by: checked by: approved by: sd - 45560 - 001 m. simmel/d. morgan m. ibarra s. miller template filename: product_spec[size_a](v.1).doc 13 6.3 plug cable over-molding 6.3.1 wire soldering this section provides an outline of the recommended plug cabl e over-molding practices for the 45339 and 45593 plug connector modules. the 45339 connector (a 16-circuit wire termination version ) 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 appropri ate solder tails working in sequence and one row at a t ime, taking care that the insulation does not become exposed more than 1mm f rom the end of the terminals. the completed assembly a fter soldering of the wires is shown below. dressing of the wires should be avoided until after the soldering and encapsulation processes are complete.
handylink? application specification revision: ecr/ecn information: sheet no. ec no: ucp2009-1982 b date: 2009/02/09 title: application specification handylink?i/o connector system 14 of 27 document number: created / revised by: checked by: approved by: sd - 45560 - 001 m. simmel/d. morgan m. ibarra s. miller template filename: product_spec[size_a](v.1).doc 14 figure 6. plug soldering set-up note : the wire bundle must be properly supported or clamped as shown, during soldering and handling, to avoid dislo dging terminals or latches from the housing prior to encapsul ation, application of a strain relief, and the final over-m old.
handylink? application specification revision: ecr/ecn information: sheet no. ec no: ucp2009-1982 b date: 2009/02/09 title: application specification handylink?i/o connector system 15 of 27 document number: created / revised by: checked by: approved by: sd - 45560 - 001 m. simmel/d. morgan m. ibarra s. miller template filename: product_spec[size_a](v.1).doc 15 6.3.2 encapsulation the next step after soldering is to pre-seal or encapsu late the back end of the connector and hold the wires in place using a silicone sealant or a low-pressure macro-melt polyamide adhesive molding. the sealant will prevent accidental shorting between adjacent terminals and discourage intrusion of over-mold resin in to the terminal and latch cavities. an illustration of the pre-seal coverage is shown below. care must be taken to ensure that no en capsulant enters the terminal or latch cavities. figure 7. encapsulated plug connector an alternate method is to combine one or more molded covers to block entire sections where void circuits are p resent, then use a pre-seal or encapsulant to hold the wires separate. thi s is illustrated below. figure 8. covered and encapsulated plug connector note: the sealant or cover should enclose the cavities u nder the latches, whether or not wires are soldered 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: ucp2009-1982 b date: 2009/02/09 title: application specification handylink?i/o connector system 16 of 27 document number: created / revised by: checked by: approved by: sd - 45560 - 001 m. simmel/d. morgan m. ibarra s. miller template filename: product_spec[size_a](v.1).doc 16 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. this will u niformly distribute mechanical loads through the wire bundle and provide m echanical support to the cable jacket and tension member. figure 9. crimp barrel installed 6.3.4 final over-molding the final pvc over-mold may be injection-molded to co mpletely cover the prepared cable assembly to provide a n 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: ucp2009-1982 b date: 2009/02/09 title: application specification handylink?i/o connector system 17 of 27 document number: created / revised by: checked by: approved by: sd - 45560 - 001 m. simmel/d. morgan m. ibarra s. miller template filename: product_spec[size_a](v.1).doc 17 6.4 design best practices the information provided so far in this document has be en related to the basic usage conditions of the handylin k? connectors. the sections that follow contain important information and guidelines for design that apply to specific applications or industrial design constraints for the end-product accessories. in all cases, molex advises that prototype assemblies be used as early in the design and development cycle as possible to simulate and assess true usa ge conditions in the actual end-products. please contact molex for technical assistance with design f easibility studies or design reviews. 6.4.0 mating over-travel clearance the handylink connectors are designed such that the corre sponding front faces fully engage and then spring ba ck 0.20mm to the final mated condition. this over-travel clearance assu res that the components of the passive latching system eng age, as illustrated in figure 11. this clearance must be accommodated in all d evice and accessory designs top assure proper function. plug connector 0.20mm over-travel clearance between connectors when mated receptacle connector hook latch
handylink? application specification revision: ecr/ecn information: sheet no. ec no: ucp2009-1982 b date: 2009/02/09 title: application specification handylink?i/o connector system 18 of 27 document number: created / revised by: checked by: approved by: sd - 45560 - 001 m. simmel/d. morgan m. ibarra s. miller template filename: product_spec[size_a](v.1).doc 18 6.4.1 plug over-mold designs supplemental guide features to align the connectors dur ing mating or un-mating are strongly recommended if a ny 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 10 00grams and is likely to experience more than 1g of acce leration 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 co nnections 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 into or complement the over-mold design as illustrated in f igures 12 and 13:
handylink? application specification revision: ecr/ecn information: sheet no. ec no: ucp2009-1982 b date: 2009/02/09 title: application specification handylink?i/o connector system 19 of 27 document number: created / revised by: checked by: approved by: sd - 45560 - 001 m. simmel/d. morgan m. ibarra s. miller template filename: product_spec[size_a](v.1).doc 19 o contouring with a lip to provide mechanical support for torque out of the a xial plane of the connectors, the over-mold must be de signed to mimic the outer surfaces of the end product and include a lip such as illustrated below. note: the axial clearance condit ion 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 end-u ser to hold the product by the connector or where a h eavy 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: ucp2009-1982 b date: 2009/02/09 title: application specification handylink?i/o connector system 20 of 27 document number: created / revised by: checked by: approved by: sd - 45560 - 001 m. simmel/d. morgan m. ibarra s. miller template filename: product_spec[size_a](v.1).doc 20 o supplemental latching and alignment posts where the mass of the end product is greater than 10 00 grams and is subject to sudden accelerations or strong v ibrations during use, a cup-style receptacle needs to be considered to adeq uately protect the connection interface. the cup-style r eceptacle should incorporate separate external latching features and sup plemental alignment posts similar to those illustrated below. note: the cup- style receptacles dimensions must restrict angular misalig nment, when mated, to within the limits specified in section 4.2. figure 14. use of a cup-style receptacle for added support and ali gnment external latching feature (each side) supplemental alignment posts cup-style receptacle (separate molded part) g uide ribs (each side)
handylink? application specification revision: ecr/ecn information: sheet no. ec no: ucp2009-1982 b date: 2009/02/09 title: application specification handylink?i/o connector system 21 of 27 document number: created / revised by: checked by: approved by: sd - 45560 - 001 m. simmel/d. morgan m. ibarra s. miller template filename: product_spec[size_a](v.1).doc 21 supplemental alignment posts must be longer than the protrusion of the plug connector posts from the base surf ace of the cup-style receptacle. further, the alignment posts centerlines m ust lie in the same plane as the centerlines of the plug connector posts to provide the greatest benefits. guide ribs are necessar y to prevent front-to back rocking motion as the de vice 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 misalignm ent. if this is not achieved, excessive wear between the connector housings a nd/or electrical discontinuities may occur.
handylink? application specification revision: ecr/ecn information: sheet no. ec no: ucp2009-1982 b date: 2009/02/09 title: application specification handylink?i/o connector system 22 of 27 document number: created / revised by: checked by: approved by: sd - 45560 - 001 m. simmel/d. morgan m. ibarra s. miller template filename: product_spec[size_a](v.1).doc 22 6.4.2 cradle designs o cup style the cup or holster style of cradle provides the greate st degree of alignment between mating connectors. whe re the end product mass is greater than 1000 grams the use of supplemental alignment posts is recommended. the alignment posts ef fective length (not including any lead-in taper) must be longer than the protrusion of the connector posts from the base surface o f the cup-style receptacle. further, the alignment posts centerlines must lie in t he same plane as the centerlines of the plug connector po sts to provide the greatest benefits. guide ribs are necessary on each side to limit front-to back rocking motion as the device is loaded i nto 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 drawings. supplemental alignment posts guide rails (each side)
handylink? application specification revision: ecr/ecn information: sheet no. ec no: ucp2009-1982 b date: 2009/02/09 title: application specification handylink?i/o connector system 23 of 27 document number: created / revised by: checked by: approved by: sd - 45560 - 001 m. simmel/d. morgan m. ibarra s. miller template filename: product_spec[size_a](v.1).doc 23 figures 16 and 17 show orthogonal views of showing dif ferences in the position and size of the openings in the cradle casing, and the pcb location for the 45560 and 45593 connectors. figure 18 shows a chamfer detail applicable to 45593. 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: ucp2009-1982 b date: 2009/02/09 title: application specification handylink?i/o connector system 24 of 27 document number: created / revised by: checked by: approved by: sd - 45560 - 001 m. simmel/d. morgan m. ibarra s. miller template filename: product_spec[size_a](v.1).doc 24 o shelf style to achieve a rocking disconnection for the end product from the cradle, a shelf style cradle design may be use d under the following conditions: no supplemental guide posts may be used; the end product may not have more than 1000 grams ma ss; side-to-side motion must be limited using end-walls or a guide rail; the vibration conditions of the end application must b e 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 drawings. connect direction disconnect rocking direction shelf (bearing surface)
handylink? application specification revision: ecr/ecn information: sheet no. ec no: ucp2009-1982 b date: 2009/02/09 title: application specification handylink?i/o connector system 25 of 27 document number: created / revised by: checked by: approved by: sd - 45560 - 001 m. simmel/d. morgan m. ibarra s. miller template filename: product_spec[size_a](v.1).doc 25 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 45593 t hat is shown in figures 16 thru 18. figures 20 throug h 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: ucp2009-1982 b date: 2009/02/09 title: application specification handylink?i/o connector system 26 of 27 document number: created / revised by: checked by: approved by: sd - 45560 - 001 m. simmel/d. morgan m. ibarra s. miller template filename: product_spec[size_a](v.1).doc 26 figure 22. connector orientation rocking direction note: orientation of the receptacle connector and the plug or cradle connector must correspond to that shown for good operation of a rocking design.
handylink? application specification revision: ecr/ecn information: sheet no. ec no: ucp2009-1982 b date: 2009/02/09 title: application specification handylink?i/o connector system 27 of 27 document number: created / revised by: checked by: approved by: sd - 45560 - 001 m. simmel/d. morgan m. ibarra s. miller template filename: product_spec[size_a](v.1).doc 27 7.0 electrical recommendations 7.1 power considerations please see the product specification, ps-44828-001, for the nominal electrical specifications. for applications w here the sustained electrical power usage requirements exceed the limits stat ed in the product specification, the use of multiple cir cuits is suggested. when the end-application is likely to encounter salt sp ray conditions, potential differences exceeding 4vdc sho uld 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 specification environment for connector components and cable assembli es (200 and 500 picosecond rise times), the handylink connectors perfo rm within specification for both differential and commo n-mode impedance. full compliance testing on finished cable assemblies will have to be undertaken to verify the performance leve l of the finished product. contact molex for further assistance regarding high speed signal transmission applications.

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