"The connector that we're currently using can't cope with our application demands.
Can you design a connector that will fit in the same space whilst meeting our performance needs and not fail in the field?"
Product: SMT battery connector
Application: Handheld security device
Quantity: 50,000pcs p/a
Issues: Even though the original connector was from a well known manufacturer it had problems with the contacts not recovering to their original positions after less than 20 cycles. Also the only plating option available was tin and the battery contacts were gold plated.
Solution: Design of a connector matching the dimensional requirements but with an improved contact design.
The new design allowed us to use lower cost Phosphor Bronze in place of Beryllium Copper whilst increasing performance to a guaranteed 100 cycles.
Gold plated contacts were used to match the contacts on the battery unit
Design brief to delivery: 8 weeks
Tooling cost: $13,000 ($0.26 per part if amortized over 50,000pcs)
Tooling refund: After 150,000pcs delivered
Result: The product design met the customers brief first time, on time, and has eliminated field failures
Added bonus of overall price reduction over previously used part of 27% (including amortized tooling costs)