Automotive Sealed Connector: Terminal Staking and Leak Testing
Connector Requirements
Automotive connector manufacturing requires IP6K7K sealing for exterior connections. Housing: PBT/PA66. Terminal: tin-plated copper alloy. Wire seal: silicone. USCAR/SAE standards for pull force, resistance and temperature cycling.
Operating range: -40°C to 125°C. CPA (connector position assurance) for locking verification.
| Component | Material | Standard | Requirement |
|---|---|---|---|
| Housing | PBT/PA66 | USCAR-2 | IP6K7K |
| Terminal | CuSn alloy | USCAR-12 | <10mΩ |
| Wire Seal | Silicone | USCAR-2 | Leak tight |
| CPA | POM | USCAR-2 | Lock confirm |
Terminal Staking
Wire crimping with pull force per wire gauge: 0.35mm² at 50N, 0.5mm² at 80N, 1.0mm² at 120N, 2.5mm² at 200N. Crimp height SPC monitoring. Microsection analysis for crimp quality.
Wire seal insertion with leak test. Terminal lance lock visual confirmation. TPA insertion for secondary lock.
| Wire Gauge | Pull Force | Crimp Height | Control |
|---|---|---|---|
| 0.35mm² | 50N | 0.8mm | SPC |
| 0.5mm² | 80N | 1.0mm | SPC tracked |
| 1.0mm² | 120N | 1.2mm | Weekly audit |
| 2.5mm² | 200N | 1.6mm | Monthly cert |
Testing
100% leak test using air decay or mass flow. Acceptance: <3cc/min at 20kPa. USCAR validation: thermal shock, thermal cycling, vibration, mechanical shock. Contact resistance before and after environmental tests.
Terminal insertion/extraction force. CPA function check. Dimensional verification of mating interface.
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