From standard to exactly the right solution.

Special manufacturing processes, extreme mechanical loads, special applications or fixed geometrical conditions: sometimes a standard solution can be fine, but not quite perfect. For us at BR-CONNECTORS, that’s not a problem, since we can adapt each and every product exactly to your requirements. Whether we’re talking about technical and mechanical components, materials, space requirements, applications and so much more.

Together with you, we will first take a close look at what changes to the product are necessary. We will then examine to what extent an existing tool needs to be rebuilt and, in the next step, we will carry out the conversion in close coordination with you. Following prototype approval, series production of your adapted standard product will begin.

Seven success stories for specially adapted standard products.

Female header

Board-to-board

What was needed
In the case of a miniature board, we needed to ensure that add-on modules could only be plugged into approved baseboards for certain functions. However, the baseboard’s existing connector system couldn’t be changed for technical reasons. Hiding and twist protection also needed to be constructively integrated.

Our solution
We produced partially assembled female headers for the add-on modules, in which several openings were entirely sealed for the purpose of coding. With this modification, all customer requirements could be met perfectly: coding, lateral protection against hiding and anti-twist protection.

Connector

Board-to-board

What was needed
For this project, it was necessary to adapt pin and socket strips to the special heights of the customer’s housing. Additionally, protection against lateral hiding and twisting had to be ensured, since the two components are not visible when merging the two boards.

Our solution
In our solution, the requirements of hiding and anti-twist protection were met on the one hand by the pan shape of the pin header and on the other by the coding function.

Pin header

Board-to-board

What was needed
When bringing together two components, the customer repeatedly suffered damage to the pin header. The reason for this could be found in tolerances in the basic housing, which made it difficult to accurately come together. What was needed was a design that prevented this.

Our solution
We developed a special insulator for the pin header, whose shape was adapted exactly to the housing to which it needed to be attached. This ensured precise guidance, so that the pin header could be fixed on the enclosure 100 percent correctly.

Screw terminal

Wire-to-board

What was needed
The starting point for this project was a standard terminal, but its torques for the customer-specific application were many times too low. The resulted in the clamping area or plastic repeatedly breaking.

Our solution
We produced the clamping area using a special steel, which was especially hard to address the requirement (but not too hard due to the risk of breakage). A special, very hard plastic was also used. This way, the customer's requirements could be met perfectly.

Wafer

Wire-to-board

What was needed
The wafer, which was the subject of this project, was to be used in the electronics of a cordless drill with waterproof components. The electronics were therefore cast after the assembly. So that the casting resin could not flow into the housing (this would have made the whole board unusable), the notches on the back of the pin header were taped by the customer before casting. In spite of this, the error rate was still around 5 percent.

Our solution
We designed and manufactured the wafer with a closed back wall so that the casting resin could no longer penetrate. The image shows the pin header before (left) and after the adjustment (right).

Spring clamp

Wire-to-board

What was needed
A commercially available spring clamp was to be used in the housing of a gate control for fixing extremely fine-stranded cables. The problem was that, due to the sharp edge of the spring, the strands broke even with a slight pull.

Our solution
We shaped the spring in a special way, so that it was rounded. In this way it was possible to prevent the strands from breaking on the cable when pulling.

Special pin header

Board-to-board

What was needed
This project focused on adapting a pin header to the housing shape so that it could be led out from the housing for attaching a specific testing adapter.

Our solution
The production of this seemingly simple component is highly complex. For example, the pin header is formed only after the application of the first insulating body in the required manner. The other insulating bodies are then applied afterward.

Special requirements?

We will find the perfect solution for you. Talk to us about your specifications.

Just get in touch with us