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There is a resurgence in press-fit connector popularity driven by increasing board complexity, the component density of today s PCAs, and the appearance of backplanes populated with active components. Press-fit connectors are typically used on very thick boards that would be difficult, or impossible, to wave-solder. Elimination of wave soldering increases manufacturing yield and allows a denser component layout on the bottom side of the board, contrary to what is dictated by wave soldering. Another advantage of using press-fit connectors is that it is a means of lead (Pb) abatement since no solder is needed for press-fit installation. Given the climate of increasing importance of environmental responsibility and the potential for lead abatement legislation passing in several countries, use of press-fit components will likely increase. Since Restriction of Hazardous Substances (RoHS) legislation allows Pb for certain products such as two-processor servers and telecommunications equipment until 2010, there is no need to solder the same connectors that are press-fitted and, thus, press-fitting significantly limits the need for Pb. Connector bodies may or may not be compatible with the thermal rigors of reflow or wave, so press-fit connectors are typically applied after all mass soldering of the PCA is completed. Further, press-pin connectors are not generally soldered into place since rework would be rendered impractical. Rework of press-fit connectors will be discussed later in this chapter.

There are many different press-fit pin configurations far too many for this chapter to review each one. Instead, three commonly used styles will be described as an introduction to press-fit technology. The first has a lead of square or rectangular cross-section that is sized to deform

A square or rectangular pin forced into round hole. This is the most primitive of press-fit techniques.

the board s plated through-hole slightly upon insertion. This is the proverbial square pin in a round hole. The lead is tapered at its end to facilitate initial PTH insertion (see Fig. 49.2). Second is the square-pin variant sometimes referred to as the H section, which consists of a sculpted rectangle, an H in cross-section, whose corners are meant to deform (see Fig. 49.3). The third and most prevalent configuration is the collapsible pin known as eye-of-theneedle (EON) (see Fig. 49.4). Upon insertion and pressing into the PTH, the EON pin folds upon itself axially in a controlled manner, as depicted in Fig. 49.5. The plated through-hole barrel is slightly deformed from the mechanical interference of the press-fit pin against it. The resultant forces from the collapsed press-fit lead against the PTH barrel wall result in stable, long-term mechanical and electrical contact.

1 2

FIGURE 49.3 H -section press-fit pin. The sculpted cross-section of the pin allows the pin to deform slightly. This deformation along with some deformation of the PTH barrel upon insertion allows for reliable mechanical and electrical contact.

FIGURE 49.5 As the EON pin is driven into the PTH barrel, its compliant section collapses inward upon itself. The resultant forces between the pin and the PTH barrel wall result in a stable, intimate mechanical and electrical contact.

Proper Loading The load necessary to apply a press-fit connector depends on a variety of factors, including pin design, pin material, pin size, pin surface finish (plating), PTH surface finish, plating thickness, pin and hole size, and the number of pins per connector. The connector manufacturer should provide the required loading per pin for each connector for proper insertion and connector seating.

Correct Design and Size Press-fit connector leads are designed to work within a tight range of PTH barrel diameters.The compliant pin normal force exerted against the PWB plated through-hole barrel wall must be maximized to anchor the connector into the PWB reliably, both for mechanical stability and electrical contact. The connector manufacturers will recommend proper PTH diameter and tolerances for their products. The resultant press-fit coupling is analogous to the solder joint. If the pin and barrel are sized properly and materials are appropriately finished, the anticipated joint life will be better than that of soldered assemblies. Also if the pin and barrel are sized correctly, the pin-to-barrel normal force will be high enough to form a gas-tight seal for long-term electrical and environmental contact reliability. The pin must be strong enough longitudinally to prevent buckling during the pressing operation. Pin normal forces must be optimized so as not to

damage the PTH barrel high enough for good contact, but light enough that the pin insertion will not damage the barrel or the PWB. 49.4.3 Reproducible Connector Press Since pressing force generally ranges from some 10s of grams to kilograms per lead, the mechanical advantage of a reproducible press machine is required for press-fit connector application.