PRODUCT: PowerFlex,
FusionLug and Custom Injection Molding
CUSTOMER END PRODUCT: High-end mainframe data storage system
APPLICATION PROBLEM: Customer required 60 amp, 5 volt flexible jumper between
back plane and power distribution pcb. Layout on both boards could not be changed
so the solution needed to match existing power pads on both pcb’s----both were different
sizes. Connector interface needed to be secured to each board and the entire assembly
needed to be fully insulated for safety and hazard issues. Captive hardware preferred.
CABLECO SOLUTION: Custom FusionLugs were designed to match existing power pads
on the back plane and power distribution pcb terminated on 6 awg PowerFlex wire for
high flexibility. To secure the connection to the back plane, custom jackscrews were
mounted to one FusionLug so it could be screwed down in to threaded PEM inserts mounted
in the backplane. PEM threaded inserts were pressed in to the other FusionLug allowing
mounting screws to come through the bottom of the power distribution pcb, in to the
FusionLug to secure it to the power distribution pcb. Custom injection molded boots
were designed for each FusionLug to insulate the entire assembly. The jackscrews were
held in place by the boot eliminating loose hardware----making it a captive hardware,
highly flexible, completely insulated solution.
