0453391600 Datasheet by Molex | Digi-Key Electronics (2024)

0453391600 Datasheet by Molex | Digi-Key Electronics (1) III/IIIIIIIIIIIIIIIIIII/IIII 12345678910111213141516 ms mwwe cuNmNs INFORMAYION m1 IS pxupwmw m MOLEX ammmc rim/moms; m: mu mum NEIY as uszn wIMom wwm PERMISSION m cuRRENTREvDEscMM 3” molexMM INCH EC NO 620216 —DRWN: AKUM 2018/05/16CHK‘D. GGA 2019/07/09APPR: GGA 2019/07/09INITIAL REVISION nucuNEMNuNaEx 1m 1w; nucvnz' REVISIONDRWN MSIMMEL 2003/07/13APPR: COMERCI 2003/07/21DOCUMENTSTATUS P1 I RELEASE DATE I 2019/07/09 041618 I Q E“T0 9 I 8 7 6 5 4 I 3 2 1

(EXAMPLE)

MODULE WITH VOIDED CIRCUITS

CLEARANCE BETWEEN

PLUG CONNECTOR AND

RECEPTACLE HOUSINGS

PLUG CONNECTOR

WITH OVERMOLD

ELECTRONIC

DEVICE

CASING

IMPORTANT: PLEASE REFER TO MOLEX

APPLICATION SPECIFICATION AS-44828-001 FOR

DETAILED DESIGN LAYOUT AND MATING REQUIREMENTS

RECOMMENDATIONS FOR CONFIGURATION

OF MATED CONNECTORS

XX

XX X

5453391607

X

XX

X

X

X

XX

XX

XXXXX

X

X

XXXX

XXX

X

X

XX

XX

X

XXX

XXXXX X XX

XXXXXXXXXX

X

XXXXX

453391605

453391604

453391603

453391602

453391600

16151413121110

9

8

76

5432

1

TERMINAL LOCATIONS (PRESENCE DENOTED BY AN X) MATERIAL NO.S

NOTES:

1. MATERIALS:

HOUSING - THERMOPLASTIC, UL94V-0, COLOR:BLACK

TERMINALS - COPPER ALLOY

LATCHES - STAINLESS STEEL

2. FINISHES: GOLD OVER NICKEL ON CONTACT AREAS,

TIN OVER NICKEL ON SOLDER AREAS.

3. PRODUCT SPECIFICATION: PS-44828-001

APPLICATION SPECIFICATION: AS-44828-001

4. PLEASE REFER TO MOLEX APPLICATION SPECIFICATION NO. AS-45339-001

FOR RECOMMENDATIONS FOR OVERMOLDING AFTER CABLE ASSEMBLY.

5. PACKAGED IN VACUUM-FORMED TRAYS (2100 PIECES PER CARTON).

NO. OF

CIRCUITS

16

8

9

10

15

14 453391606

X X X X X XXXXXX X X

X

0.20

PITCH0.8

REF.12.0

13.8

19.2

11.1

(2 PLACES)

3.00

(2 PLACES)1.1

(14 PLACES)

0.85

20.9

TERMINAL

SOLDERTAILS

22.2

THIS DRAWING CONTAINS INFORMATION THAT IS PROPRIETARY TO MOLEX ELECTRONIC TECHNOLOGIES, LLC AND SHOULD NOT BE USED WITHOUT WRITTEN PERMISSION

0.8MM HANDYLINK

PLUG CONNECTOR MODULES FOR WIRE

TERMINATION

PRODUCT CUSTOMER DRAWING

DOCUMENT NUMBER

DOC TYPE

DOC PART

REVISION

SD-45339-001

PSD

001

B

MATERIAL NUMBER CUSTOMER SHEET NUMBER

SEE CHART GENERAL MARKET 1 OF 1

CURRENT REV DESC:

EC NO: 620216

DRWN:

AKUMAR19

2018/05/16

CHK'D:

GGA

2019/07/09

APPR:

GGA

2019/07/09

INITIAL REVISION:

DRWN:

MSIMMEL

2003/07/18

APPR:

COMERCI

2003/07/21

THIRD ANGLE PROJECTION

DRAWING SERIES

B-SIZE

45339

DIMENSION UNITS

SCALE

MM

3:1

GENERAL TOLERANCES

(UNLESS SPECIFIED)

MM INCH

4 PLACES

± ±

3 PLACES

± ±

2 PLACES

±

0.1

±

1 PLACE

±

0.13

±

0 PLACES

± ±

ANGULAR TOL

±

0.5 °

DRAFT WHERE APPLICABLE

MUST REMAIN

WITHIN DIMENSIONS

FORMAT: Eng-lega-master-tb-prod-B

REVISION: D

DATE: 2018/01/18

DOCUMENT STATUS P1 RELEASE DATE 2019/07/09 04:16:18

LATCH SOLDERTAILS

HOUSING

CIRCUIT 1 CIRCUIT 16

MAX.6.4

TYP.0.9

8.7

5.9

2.4 TYP.2.8

ISOMETRIC VIEW

16 CIRCUIT MODULE

1

A

1

A

2

B

2

B

3

C

3

C

4

D

4

D

5

E

5

E

6

F

6

F

7

7

8

8

9

9

10

10

0453391600 Datasheet by Molex | Digi-Key Electronics (2) REVISION:ECR/ECN INFORMATION:TITLE: EC No:DATE:SHEET NO. DOCUMENT NUMBER: CREATED / REVISED BY:CHECKED BY:APPROVED BY:

HANDYLINK™

APPLICATION SPECIFICATION

REVISION: ECR/ECN INFORMATION: SHEET No.

EC No: UCP2006- 1391

A DATE: 2005/12/13

TITLE: APPLICATION SPECIFICATION

HANDYLINKI/O CONNECTOR SYSTEM 2 of 26

DOCUMENT NUMBER: CREATED / REVISED BY: CHECKED BY: APPROVED BY:

SD-45339-001 M. Simmel Marc Simmel Joe Comerci

TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A](V.1).DOC

HANDYLINK™

I/O CONNECTORS

44828 SMT Receptacle 45560 SMT Cradle

Connector Connector

45339 and 45593

Plug Connector Modules

0453391600 Datasheet by Molex | Digi-Key Electronics (3) (E7) SectionTable of ContentsPaqe SecfionPaqe REVISION:ECR/ECN INFORMATION:TITLE: EC No: DATE:SHEET No. DOCUMENT NUMBER: CREATED / REVISED BY: ICHECKED BY:APPROVED BY:

HANDYLINK

APPLICATION SPECIFICATION

REVISION: ECR/ECN INFORMATION: SHEET No.

EC No: UCP2006- 1391

A DATE: 2005/12/13

TITLE: APPLICATION SPECIFICATION

HANDYLINKI/O CONNECTOR SYSTEM 3 of 26

DOCUMENT NUMBER: CREATED / REVISED BY: CHECKED BY: APPROVED BY:

SD-45339-001 M. Simmel Marc Simmel Joe Comerci

TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A](V.1).DOC

Table of Contents

Section Page Section Page

1.0 Scope 3

2.0 Product Description 3

3.0 Applicable Documents and Specifications 3

4.0 Mating and Un-Mating of Connectors

4.1 Recommendations for Mating and Un-Mating 4

4.2 Mating Alignment Tolerances 4

5.0 Soldering Process Recommendations

5.1 44828 SMT Receptacle Connector 6

5.1.1 PCB Layout

5.1.2 Solder Paste Stencil Layout

5.1.3 Reflow Profile

5.1.4 Inspection

5.2 45560 SMT Cradle Connector 6

5.2.1 PCB Layout

5.2.2 Solder Paste Stencil Layout

5.2.3 Reflow Profile

5.2.4 Inspection

5.3 45339 Plug Module for Wire Termination 7

5.3.1 Applicable Wire Sizes

5.3.2 Wire Preparation

5.3.3 Inspection

5.4 45593 Plug Module for PCB Termination 7

5.4.1 PCB Layout

5.4.2 Inspection

6.0 Mechanical Design Recommendations

6.1 Mechanical Fasteners and Support 8

6.1.1 Receptacle Connector

6.1.2 Plug Connector Modules

6.1.3 Cradle Connector

6.2 Ingress Protection 10

6.3 Plug Cable Over-Molding 11

6.3.1 Wire Soldering

6.3.2 Encapsulation

6.3.3 Strain Relief

6.3.4 Final Over-Molding

6.4 Design Best Practices 14

6.4.1 Plug Over-mold Designs

6.4.2 Cradle Designs

7.0 Electrical Recommendations

7.1 Power Considerations 21

7.2 High Speed Signal Transmission 21

0453391600 Datasheet by Molex | Digi-Key Electronics (4) PRODUCT DESCRIPTIONProduct Names and Part NumbersSMT Recegtacle ConnectorsSMT Cradle ConnectorsPlug Connector ModulesDimensions, MaterialsI Platinqs, and MarkinqsAPPLICABLE DOCUMENTS AND SPECIFICATIONS REVISION: ECR/ECN INFORMATION: TITLE: SHEET No.EC No:DATE:CHECKED BY: APPROVED BY: DOCUMENT NUMBER: CREATED / REVISED BY:

HANDYLINK

APPLICATION SPECIFICATION

REVISION: ECR/ECN INFORMATION: SHEET No.

EC No: UCP2006- 1391

A DATE: 2005/12/13

TITLE: APPLICATION SPECIFICATION

HANDYLINKI/O CONNECTOR SYSTEM 4 of 26

DOCUMENT NUMBER: CREATED / REVISED BY: CHECKED BY: APPROVED BY:

SD-45339-001 M. Simmel Marc Simmel Joe Comerci

TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A](V.1).DOC

1.0 SCOPE

This specification addresses the manufacturing techniques and end-usage considerations for Molex’s 0.8mm pitch HandyLink™ I/O

Connectors. The common contact interface used in this family of connectors consists of a flat pad mated to a radiussed edge on a

compression spring blade. The flat pad is enclosed by plastic in an over-molded receptacle housing which provides a sealed

ineterface to facilitate ingress protection. The compression spring blades are extremely durable and are capable of sustaining over

20,000 mating cycles. Two “passive” latches counteract the compression springs to keep the connector pairs mated but enable

simple disconnection by the end-user.

The customer is encouraged to contact Molex with any questions regarding the application of this product.

2.0 PRODUCT DESCRIPTION

2.1 Product Names and Part Numbers

SMT Receptacle Connectors

Series: 44828

SMT Cradle Connectors

Series 45560 (Perpendicular and Parallel Mating)

Plug Connector Modules

Series 45339 (Wire Termination)

Series 45593 (PCB Termination)

2.2 Dimensions, Materials, Platings, and Markings

(See applicable sales drawings for information)

3.0 APPLICABLE DOCUMENTS AND SPECIFICATIONS

Product Specification: PS-44828-001; Sales Drawing s: SD-44828-162, SD-45560-160, SD-45560-161, SD-45339-160, SD-45593-160

0453391600 Datasheet by Molex | Digi-Key Electronics (5) .z:AmolexV MATING AND UN-MATING OF CONNECTORS Recommendations tor Matinq and Un—Malinq Mating Alignment Tolerances44828 Receptacle to 45339 or 45593 Pluq Connectors éngIJVI 5“MAX./'I- BUTHFigure 1. DIREETIDNS DREU‘DNSQ I75 REFm: .DEM/AK!» <7 eb="" both="" 0.23="" max.="" direetions="" el="" 70="" [)3="" min="" el="" revision:="" ecr/ecn="" information:="" title:="" sheet="" no.="" ec="" no:="" date:="" document="" number:="" created="" revised="" by:="" i="" checked="" by:="" i="" approved="" by:="">7>

HANDYLINK

APPLICATION SPECIFICATION

REVISION: ECR/ECN INFORMATION: SHEET No.

EC No: UCP2006- 1391

A DATE: 2005/12/13

TITLE: APPLICATION SPECIFICATION

HANDYLINKI/O CONNECTOR SYSTEM 5 of 26

DOCUMENT NUMBER: CREATED / REVISED BY: CHECKED BY: APPROVED BY:

SD-45339-001 M. Simmel Marc Simmel Joe Comerci

TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A](V.1).DOC

4.0 MATING AND UN-MATING OF CONNECTORS

This section describes the preferred methods for mating and un-mating the HandyLink connectors.

4.1 Recommendations for Mating and Un-Mating

This connector system utilizes a passive latching feature. There is no button to press to latch or unlatch. To latch, simply push the

plug into the receptacle (the connectors are polarized to discourage improper mating). To unlatch, simply grip the plug body firmly and

pull it straight out of the receptacle.

4.2 Mating Alignment Tolerances

4.2.a 44828 Receptacle to 45339 or 45593 Plug Connectors

The HandyLink plug and receptacle have been appropriately designed and toleranced to be mated and unmated by hand. The

connectors alignment features are manufactured with clearances to allow axial mating mis-alignment, as illustrated in the Figure 1,

below:

Figure 1. Receptacle to Plug Connector

Axial Alignment (units: mm)

0453391600 Datasheet by Molex | Digi-Key Electronics (6) .z:AmolexV Matin Ali nment Tolerances continued 44828 Rece tacle to 45560 Cradle Connectors _ 2° MAX. 50 M AXA ‘*Figure 2. BDTH BOTHD‘REU‘ONS DTRECTIDNS175 REFH0.20 MAX 4—1 ~BOTHDTREETTDNS [i 530 REF2.55 MAX2.3: MTN CLREVISION: ECR/ECN INFORMATION: TTTLE: SHEET No.EC No:DATE:DOCUMENT NUMBER: CREATED / REVISED BY: \ CHECKED BY: APPROVED av:

HANDYLINK

APPLICATION SPECIFICATION

REVISION: ECR/ECN INFORMATION: SHEET No.

EC No: UCP2006- 1391

A DATE: 2005/12/13

TITLE: APPLICATION SPECIFICATION

HANDYLINKI/O CONNECTOR SYSTEM 6 of 26

DOCUMENT NUMBER: CREATED / REVISED BY: CHECKED BY: APPROVED BY:

SD-45339-001 M. Simmel Marc Simmel Joe Comerci

TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A](V.1).DOC

4.2 Mating Alignment Tolerances (continued)

4.2.b 44828 Receptacle to 45560 Cradle Connectors

The HandyLink receptacle and cradle connectors alignment features are manufactured with clearances to allow some axial mating

mis-alignment as illustrated in the Figure 2, below:

Figure 2. Receptacle to

Cradle Connector Axial

Alignment (units: mm)

NOTE: Mating misalignment may significantly influence the long-term durability of the connectors. The risk of housing wear diminishes

with increasing the accuracy of connector alignment.

0453391600 Datasheet by Molex | Digi-Key Electronics (7) .z:AmolexV Clearances Between Mated PartsSOLDERING PROCESS RECOMMENDATIONS 44828 SMT Receptacle Connector45560 SMT Cradle Connector REVISION: ECR/ECN INFORMATION: T‘TLE:EC No: DATE: SHEET No. DOCUMENT NUMBER: CREATED / REVISED BY: CHECKED BY:APPROVED BY:

HANDYLINK

APPLICATION SPECIFICATION

REVISION: ECR/ECN INFORMATION: SHEET No.

EC No: UCP2006- 1391

A DATE: 2005/12/13

TITLE: APPLICATION SPECIFICATION

HANDYLINKI/O CONNECTOR SYSTEM 7 of 26

DOCUMENT NUMBER: CREATED / REVISED BY: CHECKED BY: APPROVED BY:

SD-45339-001 M. Simmel Marc Simmel Joe Comerci

TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A](V.1).DOC

4.3 Clearances Between Mated Parts

The HandyLink connectors are designed such that the corresponding front faces fully engage and then spring back 0.20mm to the

final mated condition. This over-travel clearance assures that the components of the passive latching system engage. Please see

Section 6.4 Design Best Practices for further detailed information.

5.0 SOLDERING PROCESS RECOMMENDATIONS

5.1 44828 SMT Receptacle Connector

5.1.1 PCB Layout

See the applicable Sales Drawing for an illustration of the recommended PCB layout. Contact Molex if further assistance is required.

5.1.2 Solder Paste Stencil Layout

See Sales Drawing for solderable surfaces. Contact Molex if further assistance is required.

5.1.3 Reflow Profile

While the production solder reflow profile is typically established by the customer, based on their specific application, generic reflow

profiles can be found in Product Specification PS-44828-001. The profiles are provided for reference purposes only.

5.1.4 Inspection

Solder joints should be inspected using established conventional methods.

5.2 45560 SMT Cradle Connector

5.2.1 PCB Layout

See the applicable Sales Drawings for illustrations of the recommended PCB pad layouts. Contact Molex if further assistance is

required.

5.2.2 Solder Paste Stencil Layout

See Sales Drawing for recommended PCB pad layout and solder paste thickness.

0453391600 Datasheet by Molex | Digi-Key Electronics (8) (E7) 45339 Plug Modulator Wire Termination45593 Plug Modulator PCB Termin n REVISION:ECR/ECN INFORMATION:TITLE: EC No:DATE:SHEET No. DOCUMENT NUMBER: CREATED / REVISED BY:CHECKED BY:APPROVED BY:

HANDYLINK

APPLICATION SPECIFICATION

REVISION: ECR/ECN INFORMATION: SHEET No.

EC No: UCP2006- 1391

A DATE: 2005/12/13

TITLE: APPLICATION SPECIFICATION

HANDYLINKI/O CONNECTOR SYSTEM 8 of 26

DOCUMENT NUMBER: CREATED / REVISED BY: CHECKED BY: APPROVED BY:

SD-45339-001 M. Simmel Marc Simmel Joe Comerci

TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A](V.1).DOC

5.2.3 Reflow Profile

While the production solder reflow profile is typically established by the customer, based on their specific application, generic reflow

profiles can be found in Product Specification PS-44828-001. The profiles are provided for reference purposes only.

5.2.4 Inspection

Solder joints should be inspected using established conventional methods.

5.3 45339 Plug Module for Wire Termination

5.3.1 Applicable Wire Sizes

Copper conductor size: 22 to 34 AWG (stranded wires are recommended for flexibility) may be used,

however, 22 to 28 AWG conductors are necessary to transmit 1.5 Amperes DC continuously.

Maximum insulation diameter: 1.6mm

NOTE: Small conductor sizes are suitable for the transmission of digital signals, and may improve wire bundle flexibility and harness

workability.

5.3.2 Wire Preparation

Strip length: 2.0 ~ 2.5mm

Pre-tinning is recommended.

5.3.3 Inspection

Solder joints should be inspected using established conventional methods.

5.4 45593 Plug Module for PCB Termination

5.4.1 PCB Layout

See the applicable Sales Drawing for an illustration of the recommended PCB hole layout.

5.4.2 Inspection

Solder joints should be inspected using established conventional methods.

0453391600 Datasheet by Molex | Digi-Key Electronics (9) .z:AmolexV MECHANICAL MOUNTING RECOMMENDATIONSMechanical Fasteners and Sugpon DOCUMENT NUMBER:+ 2 . +ROVSMTN 20' OWN A “WAX-. (HUMAX. ‘ mow.[LEARANCE EHAMFER:\[ [ET LEW 0.80mumuumu [ALL AROUND),,,,,,,,,,,,,,,;;,,,,:.§3.10 MW. 7 4—» 0.25 MAX.AFRONT VTEW SECTTDN ArAFigure 3A.REVISION: ECR/ECN INFORMATION: TTTLE: SHEET N0.EC No:DATE: CREATED / REVISED BY:CHECKED BY:APPROVED BY:

HANDYLINK

APPLICATION SPECIFICATION

REVISION: ECR/ECN INFORMATION: SHEET No.

EC No: UCP2006- 1391

A DATE: 2005/12/13

TITLE: APPLICATION SPECIFICATION

HANDYLINKI/O CONNECTOR SYSTEM 9 of 26

DOCUMENT NUMBER: CREATED / REVISED BY: CHECKED BY: APPROVED BY:

SD-45339-001 M. Simmel Marc Simmel Joe Comerci

TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A](V.1).DOC

6.0 MECHANICAL MOUNTING RECOMMENDATIONS

6.1 Mechanical Fasteners and Support

6.1.1 Receptacle Connector

Molex recommends that the receptacle connector be mounted within the end-application enclosure such that it is recessed by 1.6 to

2.4mm from the outermost faces and with a 0.10mm maximum clearance with the casing inner walls. Such a recess provides multiple

advantages in terms of protecting the contact surfaces from accidental impact with foreign objects, providing mechanical support when

the mating plug connector assembly is torqued by abusive handling, and helps to reduce direct contact with hand oils or other

contamination. See Figures 3A and 3B, below, for recommendations on recess dimensions.

Figure 3A. Receptacle Connector Recess When Mating with the Plug Only (units: mm)

0453391600 Datasheet by Molex | Digi-Key Electronics (10) (E7) 4~ 2.40 MAX.0.10 MAX. 1.60 M‘N.CLEARANCE 21.00 M‘N.5.EOM\N. W[HAMFERt45°>< 0.40="" mm.="" x="" b="" front="" v‘ew="" sect‘on="" 878="" figure="" sb.="" revision:="" ecr/ecn="" information:="" t‘tle:="" sheet="" no.="" ec="" no:="" date:="" document="" number:="" created="" revised="" by:="" ‘="" checked="" by:="" ‘="" approved="" by:="">

HANDYLINK

APPLICATION SPECIFICATION

REVISION: ECR/ECN INFORMATION: SHEET No.

EC No: UCP2006- 1391

A DATE: 2005/12/13

TITLE: APPLICATION SPECIFICATION

HANDYLINKI/O CONNECTOR SYSTEM 10 of 26

DOCUMENT NUMBER: CREATED / REVISED BY: CHECKED BY: APPROVED BY:

SD-45339-001 M. Simmel Marc Simmel Joe Comerci

TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A](V.1).DOC

Figure 3B. Receptacle Connector Recess When Mating with the Plug or Cradle Connectors (units: mm)

Wherever possible, the 0.10 maximum clearance condition with the receptacle should be minimized by utilizing a clam-shell style

package design.

6.1.2 Plug Connector Module

The plug connector module is intended to be used as a part of a assembly using either direct wire soldering (45339) or using an

intermediary PCB (45593). Overmolding and/or clam shell style covers must be used to protect the wire connections and the

appropriate service loops and wire strain reliefs must be incorporated in a cable assembly to prevent damage during use. Please refer

to section 6.3 for further details about the over-molding process.

If the connector module is used as a stand-alone component on a PCB, the mating interface must be adequately supported. Please

refer to section 6.4.2 for further details concerning cradle design recommendations.

6.1.3 Cradle Connector

The cradle connector is designed to be fastened to the PCB with screws. See Sales Drawings for recommended screw size and

positions. Please refer to section 6.4.2 for further details concerning cradle design recommendations.

0453391600 Datasheet by Molex | Digi-Key Electronics (11) (E) lngress Protection REVISION: ECR/ECN INFORMATION:TITLE: EC No:DATE: SHEET NO. DOCUMENT NUMBER: CREATED / REVISED BY: ICHECKED BY:APPROVED BY:

HANDYLINK

APPLICATION SPECIFICATION

REVISION: ECR/ECN INFORMATION: SHEET No.

EC No: UCP2006- 1391

A DATE: 2005/12/13

TITLE: APPLICATION SPECIFICATION

HANDYLINKI/O CONNECTOR SYSTEM 11 of 26

DOCUMENT NUMBER: CREATED / REVISED BY: CHECKED BY: APPROVED BY:

SD-45339-001 M. Simmel Marc Simmel Joe Comerci

TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A](V.1).DOC

6.2 Ingress Protection

Ingress protection, as described by IEC 60529, is a function of the customers enclosure. The HandyLink Receptacle Connector has

been designed to facilitate enclosure design when ingress protection is required. The interfaces between the metal and plastic

components of the connector are sealed to discourage intrusion of dust and liquid through the connector into the enclosure. The

customer is expected to design an appropriate seal around the periphery of the connector to adequately seal the finished enclosure.

Contact Molex for additional information.

Gaskets may be applied to the top and sides, or

front surfaces.

The bottom surface, once soldered, forms a continuous seal with the PCB

Figure 4. Sealing to achieve ingress protection with the receptacle connector

0453391600 Datasheet by Molex | Digi-Key Electronics (12) Plug Cable Over-Molding Figure 5. REVISION: ECR/ECN INFORMATION:TITLE: EC No: DATE:SHEET No. DOCUMENT NUMBER: CREATED / REVISED BY: ICHECKED BY:APPROVED BY:

HANDYLINK

APPLICATION SPECIFICATION

REVISION: ECR/ECN INFORMATION: SHEET No.

EC No: UCP2006- 1391

A DATE: 2005/12/13

TITLE: APPLICATION SPECIFICATION

HANDYLINKI/O CONNECTOR SYSTEM 12 of 26

DOCUMENT NUMBER: CREATED / REVISED BY: CHECKED BY: APPROVED BY:

SD-45339-001 M. Simmel Marc Simmel Joe Comerci

TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A](V.1).DOC

6.3 Plug Cable Over-Molding

6.3.1 Wire Soldering

This section provides an outline of the recommended plug cable over-molding practices

for the 45339 and 45593 plug connector modules. The 45339 connector (a 16-circuit wire termination version) is shown, below, prior to

soldering. Please note the following features:

Latch soldertails (2 places) Wire soldertails (2 rows)

Cavities under the latches (2 places)

Figure 5. Soldertail side of the plug connector

Pre-tinned wires should be terminated to the appropriate solder tails working in sequence and one row at a time, taking care that

the insulation does not become exposed more than 1mm from the end of the terminals. The completed assembly after soldering of

the wires is shown below. Dressing of the wires should be avoided until after the soldering and encapsulation processes are

complete.

0453391600 Datasheet by Molex | Digi-Key Electronics (13) Figure 6. REVISION:ECR/ECN INFORMATION:TITLE: EC No:DATE:SHEET No. DOCUMENT NUMBER: CREATED / REVISED BY:CHECKED BY:APPROVED BY:

HANDYLINK

APPLICATION SPECIFICATION

REVISION: ECR/ECN INFORMATION: SHEET No.

EC No: UCP2006- 1391

A DATE: 2005/12/13

TITLE: APPLICATION SPECIFICATION

HANDYLINKI/O CONNECTOR SYSTEM 13 of 26

DOCUMENT NUMBER: CREATED / REVISED BY: CHECKED BY: APPROVED BY:

SD-45339-001 M. Simmel Marc Simmel Joe Comerci

TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A](V.1).DOC

Figure 6.

Plug Soldering Set-Up

NOTE: The wire bundle must be properly supported or clamped

as shown, during soldering and handling, to avoid dislodging

terminals or latches from the housing prior to encapsulation,

application of a strain relief, and the final over-mold.

0453391600 Datasheet by Molex | Digi-Key Electronics (14) Figure 7.Figure 8. REVISION:ECR/ECN INFORMATION:TITLE: EC No:DATE:SHEET No. DOCUMENT NUMBER: CREATED / REVISED BY:CHECKED BY:APPROVED BY:

HANDYLINK

APPLICATION SPECIFICATION

REVISION: ECR/ECN INFORMATION: SHEET No.

EC No: UCP2006- 1391

A DATE: 2005/12/13

TITLE: APPLICATION SPECIFICATION

HANDYLINKI/O CONNECTOR SYSTEM 14 of 26

DOCUMENT NUMBER: CREATED / REVISED BY: CHECKED BY: APPROVED BY:

SD-45339-001 M. Simmel Marc Simmel Joe Comerci

TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A](V.1).DOC

6.3.2 Encapsulation

The next step after soldering is to pre-seal or encapsulate the back end of the connector and hold the wires in place using a silicone

sealant or a low-pressure Macro-melt polyamide adhesive molding. The sealant will prevent accidental shorting between adjacent

terminals and discourage intrusion of over-mold resin into the terminal and latch cavities. An illustration of the pre-seal coverage is

shown below. Care must be taken to ensure that no encapsulant enters the terminal or latch cavities.

Figure 7.

Encapsulated plug connector

An alternate method is to combine one or more molded ‘covers’ to block entire sections where void circuits are present, then use a

pre-seal or encapsulant to hold the wires separate. This is illustrated below.

Figure 8.

Covered and encapsulated plug connector

NOTE: The sealant or cover should enclose the cavities under the latches, whether or not wires are soldered to the latches. Omission

of this step would allow the final over-mold resin to extrude into cavities in the housing that could disable latch and terminal function.

0453391600 Datasheet by Molex | Digi-Key Electronics (15) Figure 9.Figure 10.REVISION: ECR/ECN INFORMATION: TITLE: SHEET No.EC No:DATE: DOCUMENT NUMBER: CREATED / REVISED BY:wAPPROVED EIY:

HANDYLINK

APPLICATION SPECIFICATION

REVISION: ECR/ECN INFORMATION: SHEET No.

EC No: UCP2006- 1391

A DATE: 2005/12/13

TITLE: APPLICATION SPECIFICATION

HANDYLINKI/O CONNECTOR SYSTEM 15 of 26

DOCUMENT NUMBER: CREATED / REVISED BY: CHECKED BY: APPROVED BY:

SD-45339-001 M. Simmel Marc Simmel Joe Comerci

TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A](V.1).DOC

6.3.3 Strain Relief

Molex strongly recommends the use of a crimp barrel or ferrule over the wire bundle

(including ground or drain wire) that also captures the cable jacket and tension member, if used. This will uniformly distribute

mechanical loads through the wire bundle and provide mechanical support to the cable jacket and tension member.

Figure 9.

Crimp barrel installed

6.3.4 Final Over-Molding

The final PVC over-mold may be injection-molded to completely cover the prepared cable assembly to provide an esthetically

pleasing finished product. Please see Section 6.4.1 for a discussion of design best practices for the over-mold.

Figure 10.

Finished over-mold (shown transparent)

0453391600 Datasheet by Molex | Digi-Key Electronics (16) (E) Design Best Practi sMating Over-Travel Clearance REVISION: ECR/ECN INFORMATION: TITLE: SHEET NO.EC No: DATE: DOCUMENT NUMBER: CREATED / REVISED BY: I CHECKED BY: I APPROVED BY:

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APPLICATION SPECIFICATION

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6.4 Design Best Practices

The information provided so far in this document has been related to the basic usage conditions of the HandyLink connectors. The

sections that follow contain important information and guidelines for design that apply to specific applications or industrial design

constraints for the end-product accessories. In all cases, Molex advises that prototype assemblies be used as early in the design and

development cycle as possible to simulate and assess true usage conditions in the actual end-products.

Please contact Molex for technical assistance with design feasibility studies or design reviews.

6.4.0 Mating Over-Travel Clearance

The HandyLink connectors are designed such that the corresponding front faces fully engage and then spring back 0.20mm to the

final mated condition. This over-travel clearance assures that the components of the passive latching system engage, as illustrated in

Figure 11. This clearance must be accommodated in all device and accessory designs top assure proper function.

Plug Connector

0.20mm over-travel

clearance between

connectors when mated

Receptacle Connector

Hook

Latch

0453391600 Datasheet by Molex | Digi-Key Electronics (17) Figure 12. REVISION: ECR/ECN INFORMATION: TITLE: SHEET NO.EC No:DATE:DOCUMENT NUMBER: CREATED / REVISED BY: I CHECKED BY: I APPROVED BY:

HANDYLINK

APPLICATION SPECIFICATION

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TITLE: APPLICATION SPECIFICATION

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6.4.1 Plug Over-Mold Designs

Supplemental guide features to align the connectors during mating or un-mating are strongly recommended if any of the following

conditions are present:

o A great deal of curvature in the end product (such as that illustrated, below);

o The accessory cable is stiff or bent abruptly;

o The mass of the end-product itself is greater than 1000grams and is likely to experience more than 1g of acceleration during use or

under vibration;

o The cable connection and disconnection cycles are numerous (more than 5000 cycles);

o There is significant risk of the end users pulling at connections in off-axis directions.

Figure 12. Example of an application

with a great degree of curvature near

the connector interface.

Supplemental guide features may be incorporated into or complement the over-mold design as illustrated in Figures 12 and 13:

0453391600 Datasheet by Molex | Digi-Key Electronics (18) Figure 13. REVISION: ECR/ECN INFORMATION: TITLE: SHEET No.EC No:DATE:DOCUMENT NUMBER: CREATED / REVISED BY: CHECKED BV: APPROVED BY:

HANDYLINK

APPLICATION SPECIFICATION

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EC No: UCP2006- 1391

A DATE: 2005/12/13

TITLE: APPLICATION SPECIFICATION

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o Contouring with a Lip

To provide mechanical support for torque out of the axial plane of the connectors, the over-mold must be designed to mimic the

outer surfaces of the end product and include a lip such as illustrated below. NOTE: The axial clearance condition between the

connectors noted in section 4.2 must be maintained.

Figure 13. Example of an over-mold with contouring and a lip

This type of design will provide support for the end-user to hold the product by the connector or where a heavy or stiff accessory cable

is used.

Over-molded lip

Off-axis

Torque

directions

Surfaces are contoured

to mimic the end product

0453391600 Datasheet by Molex | Digi-Key Electronics (19) Figure 14.REVISION: ECR/ECN INFORMATION: TITLE: SHEET No.EC No:DATE: DOCUMENT NUMBER: CREATED / REVISED BY: ‘ CHECKED BY: ‘ APPROVED BY:

HANDYLINK

APPLICATION SPECIFICATION

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EC No: UCP2006- 1391

A DATE: 2005/12/13

TITLE: APPLICATION SPECIFICATION

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o Supplemental Latching and Alignment Posts

Where the mass of the end product is greater than 1000 grams and is subject to sudden accelerations or strong vibrations during

use, a cup-style receptacle needs to be considered to adequately protect the connection interface. The cup-style receptacle should

incorporate separate external latching features and supplemental alignment posts similar to those illustrated below. NOTE: The cup-

style receptacles dimensions must restrict angular misalignment, when mated, to within the limits specified in Section 4.2.

Figure 14. Use of a cup-style receptacle for added support and alignment

External latching feature (each side)

Supplemental alignment posts

Cup-style receptacle (separate

molded part)

Guide ribs (each side)

0453391600 Datasheet by Molex | Digi-Key Electronics (20) (E7) REVISIONECR/ECN INFORMATIONTITLE: EC No:DATE:SHEET No. DOCUMENT NUMBER: CREATED / REVISED BY:CHECKED BYAPPROVED BY:

HANDYLINK

APPLICATION SPECIFICATION

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TITLE: APPLICATION SPECIFICATION

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Supplemental alignment posts must be longer than the protrusion of the plug connector posts from the base surface of the cup-style

receptacle. Further, the alignment posts centerlines must lie in the same plane as the centerlines of the plug connector posts to

provide the greatest benefits. Guide ribs are necessary to prevent front-to back rocking motion as the device is loaded into the cup-

style receptacle.

NOTE: The fastening of the cup-style receptacle to the over-molded plug must be kept tight to avoid misalignment. If this is not

achieved, excessive wear between the connector housings and/or electrical discontinuities may occur.

0453391600 Datasheet by Molex | Digi-Key Electronics (21) Figure 15. REVISION: ECR/ECN INFORMATION: TITLE: SHEET No.EC No: DATE: DOCUMENT NUMBER: CREATED / REVISED BY: I CHECKED BY: I APPROVED BY:

HANDYLINK

APPLICATION SPECIFICATION

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A DATE: 2005/12/13

TITLE: APPLICATION SPECIFICATION

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TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A](V.1).DOC

6.4.2 Cradle Designs

o Cup Style

The cup or holster style of cradle provides the greatest degree of alignment between mating connectors. Where the end product

mass is greater than 1000 grams the use of supplemental alignment posts is recommended. The alignment posts effective length (not

including any lead-in taper) must be longer than the protrusion of the connector posts from the base surface of the cup-style receptacle.

Further, the alignment posts centerlines must lie in the same plane as the centerlines of the plug connector posts to provide the greatest

benefits. Guide ribs are necessary on each side to limit front-to back rocking motion as the device is loaded into the cup-style cradle.

Figure 15. Cup-Style Cradle Features

NOTE: For details about mounting the connectors to the PCB and the use of

fasteners, please refer to the applicable Sales Drawings.

Supplemental

Alignment Posts

Guide Rails

(each side)

0453391600 Datasheet by Molex | Digi-Key Electronics (22) iii fifiTi ""“"““‘“““ ”‘IH4- 21.30 —7 Suppiemgmui Aiignmgni F’usis 7 0.50II I i E 0,..03'45‘;moJ 1 E i ’ \ j A _ ,3-95 93° / SEE DETAIL Y DE T A IL TPKB PEBCSECTION xix QEU‘ON Z ZFigure 16. Figure 17. Figure 18.REVISION: ECH/ECN INFORMATION: TITLE: SHEET NO.EC No:DATE:DOCUMENT NUMBER: CREATED / REVISED BY: CHECKED BY: I APPROVED BY:

HANDYLINK

APPLICATION SPECIFICATION

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A DATE: 2005/12/13

TITLE: APPLICATION SPECIFICATION

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Figures 16 and 17 show orthogonal views of showing differences in the position and size of the openings in the cradle casing, and

the PCB location for the 45560 and 45593 connectors. Figure 18 shows a chamfer detail applicable to 45593.

Figure 16. Cradle Detail (45560) Figure 17. Cradle Detail (45593) Figure 18. Detail from Fig. 17.

(units: mm) (units: mm) (units: mm)

0453391600 Datasheet by Molex | Digi-Key Electronics (23) (é) ‘r‘r‘r>Figure 19.REVISION: ECR/ECN INFORMATION: TITLE: SHEET No.EC No:DATE:DOCUMENT NUMBER: CREATED / REVISED BY: CHECKED BY: APPROVED BY:

HANDYLINK

APPLICATION SPECIFICATION

REVISION: ECR/ECN INFORMATION: SHEET No.

EC No: UCP2006- 1391

A DATE: 2005/12/13

TITLE: APPLICATION SPECIFICATION

HANDYLINKI/O CONNECTOR SYSTEM 23 of 26

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SD-45339-001 M. Simmel Marc Simmel Joe Comerci

TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A](V.1).DOC

o Shelf Style

To achieve a rocking disconnection for the end product from the cradle, a shelf style cradle design may be used under the

following conditions:

No supplemental guide posts may be used;

The end product may not have more than 1000 grams mass;

Side-to-side motion must be limited using end-walls or a guide rail;

The vibration conditions of the end application must be limited.

Figure 19. Shelf-Style Cradle Features

NOTE: For details about mounting the connectors to the PCB and the use of

fasteners, please refer to the applicable Sales Drawings.

Connect

Direction

Disconnect

Rocking

Direction

Shelf

(Bearing Surface)

0453391600 Datasheet by Molex | Digi-Key Electronics (24) (E7) MAINTAIN [LOSECLEARANCES TO PREVENT BACK SUPPORT STDEETOESTDE 'R’OCKINE’ (REQUIRED)W+FEB‘R’UCKTNE‘REEEPTACLE(“828) PIVOT POINTCONNECTOR4-» 6.50MTNTMUMPCBWS E CTTO N WEWFigure 20. Figure 21.REVISION ECR/ECN INFORMATION TITLE: SHEET No.EC No:DATE: DOCUMENT NUMBER: CREATED / REVISED BY:CHECKED BYAPPROVED BY:

HANDYLINK

APPLICATION SPECIFICATION

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EC No: UCP2006- 1391

A DATE: 2005/12/13

TITLE: APPLICATION SPECIFICATION

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SD-45339-001 M. Simmel Marc Simmel Joe Comerci

TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A](V.1).DOC

In addition to the differences in the position and size of the openings in the cradle casing, the PCB location for the 45560 and 45593

connectors, and the chamfer detail applicable to 45593 that is shown in Figures 16 thru 18. Figures 20 through 22 illustrate details

necessary to achieve a good rocking design.

Figure 20. Front View of Shelf-Style Cradle Figure 21. Section View of Shelf-Style Cradle (units: mm)

0453391600 Datasheet by Molex | Digi-Key Electronics (25) Figure 22. REVISION:ECR/ECN INFORMATION:TITLE: EC No:DATE:SHEET No. DOCUMENT NUMBER:CREATED / REVISED BY: CHECKED BY:APPROVED BY:

HANDYLINK

APPLICATION SPECIFICATION

REVISION: ECR/ECN INFORMATION: SHEET No.

EC No: UCP2006- 1391

A DATE: 2005/12/13

TITLE: APPLICATION SPECIFICATION

HANDYLINKI/O CONNECTOR SYSTEM 25 of 26

DOCUMENT NUMBER: CREATED / REVISED BY: CHECKED BY: APPROVED BY:

SD-45339-001 M. Simmel Marc Simmel Joe Comerci

TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A](V.1).DOC

Figure 22. Connector Orientation

Rocking Direction

NOTE: Orientation of the receptacle connector and

the plug or cradle connector must correspond to that

shown for good operation of a rocking design.

0453391600 Datasheet by Molex | Digi-Key Electronics (26) AmolexV.z: Electrical RecommendationsPower ConsiderationsHigh Sgeed Signal Transmission REVISION:ECR/ECN INFORMATION: TITLE: EC No:DATE: SHEET No. DOCUMENT NUMBER: CREATED / REVISED BY: CHECKED BY:APPROVED BY:

HANDYLINK

APPLICATION SPECIFICATION

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TITLE: APPLICATION SPECIFICATION

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7.0 Electrical Recommendations

7.1 Power Considerations

Please see the Product Specification, PS-44828-001, for the nominal electrical specifications. For applications where the sustained

electrical power usage requirements exceed the limits stated in the product specification, the use of multiple circuits is suggested.

When the end-application is likely to encounter salt spray conditions, potential differences exceeding 4VDC should be separated by

more than one terminal position (i.e. 1.6mm or more) to avoid galvanic corrosion between circuits.

7.2 High Speed Signal Transmission

Testing has shown that under the USB 2.0 Specification environment for connector components and cable assemblies (200 and

500 picosecond rise times), the HandyLink connectors perform within specification for both differential and common-mode impedance.

Full compliance testing on finished cable assemblies will have to be undertaken to verify the performance level of the finished

product.

Contact Molex for further assistance regarding high speed signal transmission applications.

0453391600 Datasheet by Molex | Digi-Key Electronics (2024)
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