FirstSpear
- Sep 13, 2014
- 5
- Joined
- Sep 13, 2014
- Messages
- 5
Howdy.
Damage to wire leads (cable/plug connections) occur mostly in one of two places: at the point of cable exit from the body of the plug due to inadequate strain relief, and inside the plug at the solder connections.
Strain relief is often either non-existent or is far too rigid, disallowing a gentle curve and allowing only sharp right-angle bends, which usually breaks the copper strands inside the inner insulation. Strain relief problems can be overcome to a large extent if addressed when the cable is new, by adding extra support using coil springs (from biros), Sugru, tape, etc.; anything that smooths away that harsh right-angle.
I've recently had problems with two USB to iPhone 30pin cables, as have thousands of other people - read the reviews on Amazon. With the first I suspect a cheap plug as when I opened it the soldered connections were good - I've yet to check for continuity. The second exhibited a wire snapped off one of the four solder connections.
These solder connections are tiny and very close together, and while I am capable of resoldering them, I'd rather stop the problem from happening in the first place. The space inside the plug is, relatively, very large, and there is plenty of room for the cores to move about enabling work-hardness of solder or copper. The inner insulated cores are not held rigidly inside the outer sleeve, which slides off easily; a situation necessary for stripping, and so linear and twisting movements of the inner cores will be transferred along the cable and into the the free ends inside the body of the plug. I'm wondering about filling the plug cavity with something that will set around the wires and the solder connections holding the whole join rigid. If the strain relief problem has been addressed, then this should increase the life of the cable greatly. But what to fill it with?
I'm thinking of filling the cavity without dismantling the plug's body by making a small hole and injecting something inside. The only syringes readily available are for refilling ink cartridges, and the needles are quite thick, and blunt, but would probably work. The only substance I can think of that would be liquid enough to actually exit the syringe and then set without loss of mass is transparent silicone sealant, and might be later removeable should that be desired for any reason; the coloured versions I've used have all been too viscous.
Any ideas or suggestions concerning materials or concept? Also, comments on the conductivity of these sealants welcome - I've read contradictory opinions regarding silicone in other circumstances.
I'm in the UK, so if suggesting materials, I would hugely appreciate details that allow me to recognise the substance, and not just the brand, which usually differs.
Ta muchly.
Damage to wire leads (cable/plug connections) occur mostly in one of two places: at the point of cable exit from the body of the plug due to inadequate strain relief, and inside the plug at the solder connections.
Strain relief is often either non-existent or is far too rigid, disallowing a gentle curve and allowing only sharp right-angle bends, which usually breaks the copper strands inside the inner insulation. Strain relief problems can be overcome to a large extent if addressed when the cable is new, by adding extra support using coil springs (from biros), Sugru, tape, etc.; anything that smooths away that harsh right-angle.
I've recently had problems with two USB to iPhone 30pin cables, as have thousands of other people - read the reviews on Amazon. With the first I suspect a cheap plug as when I opened it the soldered connections were good - I've yet to check for continuity. The second exhibited a wire snapped off one of the four solder connections.
These solder connections are tiny and very close together, and while I am capable of resoldering them, I'd rather stop the problem from happening in the first place. The space inside the plug is, relatively, very large, and there is plenty of room for the cores to move about enabling work-hardness of solder or copper. The inner insulated cores are not held rigidly inside the outer sleeve, which slides off easily; a situation necessary for stripping, and so linear and twisting movements of the inner cores will be transferred along the cable and into the the free ends inside the body of the plug. I'm wondering about filling the plug cavity with something that will set around the wires and the solder connections holding the whole join rigid. If the strain relief problem has been addressed, then this should increase the life of the cable greatly. But what to fill it with?
I'm thinking of filling the cavity without dismantling the plug's body by making a small hole and injecting something inside. The only syringes readily available are for refilling ink cartridges, and the needles are quite thick, and blunt, but would probably work. The only substance I can think of that would be liquid enough to actually exit the syringe and then set without loss of mass is transparent silicone sealant, and might be later removeable should that be desired for any reason; the coloured versions I've used have all been too viscous.
Any ideas or suggestions concerning materials or concept? Also, comments on the conductivity of these sealants welcome - I've read contradictory opinions regarding silicone in other circumstances.
I'm in the UK, so if suggesting materials, I would hugely appreciate details that allow me to recognise the substance, and not just the brand, which usually differs.
Ta muchly.