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Stiff tail troubles The new stiffer hybrid tail flexes the interconnect card on the rod by about 1 to 1.5 mm Some tilt in the connector as well Force needed to push board flat ~ 250g Rod tested fine at room temperature, but not in the cold (could be open connectors)

Stiff tail troubles

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Stiff tail troubles. The new stiffer hybrid tail flexes the interconnect card on the rod by about 1 to 1.5 mm Some tilt in the connector as well Force needed to push board flat ~ 250g Rod tested fine at room temperature, but not in the cold (could be open connectors). - PowerPoint PPT Presentation

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Page 1: Stiff tail troubles

Stiff tail troubles• The new stiffer hybrid tail

flexes the interconnect card on the rod by about 1 to 1.5 mm

• Some tilt in the connector as well

• Force needed to push board flat ~ 250g

• Rod tested fine at room temperature, but not in the cold (could be open connectors)

Page 2: Stiff tail troubles

Old, softer tail in the same position

• Some flexing of the PCB board

• No tilt in the connector

• Force needed to push board flat ~ 80g

Page 3: Stiff tail troubles

New bends to the tail

• Pos. 3 on the rod (smallest gap between module and interconnect card)

• Tail bent in situ on the rod

• Bends are close to c-fiber than before

• Some improvement, but still deflection of the PCB

Page 4: Stiff tail troubles

New bends to the tail

• Same bend moved to pos 5 (larger gap)

• No deflection of the PCB

• But: Highest point of tail is ~1.5mm above stay-clear, not acceptable

Page 5: Stiff tail troubles

New bends to the tail• Tail bent like original (soft

tail)• Added “kinks” with tweezers,

while module was on the rod

•Less deflection of the PCB (~ 100g)

•Also works in pos. 5

•The 2 modules used for these tests showed no opens in the tail after extensive bending

Page 6: Stiff tail troubles

The tail tale continues• The goal is to bend the

tails only on the vacuum fixture, not on the rod, to avoid putting stress on the connector

• Try out new bending tools (the tweezers used previously crease the tail dramatically):– non-tapered rounded

tweezers– Modified sur-clip pliers

Page 7: Stiff tail troubles

Bending with the new tools

• Was not able to repeat the tail bend shape previously developed (see slide 5) by bending on the vacuum fixture with either tool

• Try different shapes

• Tweezers work better than surclip pliers

Page 8: Stiff tail troubles

Best bend so far

• Small radius on top, large radius on bottom• Use new tweezers to make the small radius bend at the connector end, and

bend tail back over the module frame by hand to make bottom part more rounded

• Board deflection ~80g• This seems to be as good as it can get without bending the tail while the

module is on the rod• A SS6 rod was assembled using this bend on all modules, still needs to be

electrically tested in the cold