Pitch 3.96 mm [.156] connectors 396 series

The 396 Series connectors are a family of 3.96 mm (.156 inch) pitch connectors designed for power and signal applications that require reliable, high-current connections. These connectors are commonly used in automotive, industrial, and consumer electronics applications where space efficiency and secure connections are essential. 

1. Key Features of 396 Series Connectors

• 3.96 mm (.156”) Pitch: Provides a balance between compact size and power-handling capability.
• High Current Capacity: Typically rated for up to 7A per circuit, depending on wire size and terminal type.
• Wire-to-Wire & Wire-to-Board Options: Supports both direct wiring and PCB mounting.
• Multiple Pin Configurations: Available in 2 to 24 positions, in both single- and dual-row layouts.
• Locking Mechanisms:
• Friction locks for basic retention.
• Latching features for enhanced security in high-vibration environments.
• Polarized Design: Prevents incorrect mating and misalignment.
• Durable Materials:
• Housing: Constructed from high-temperature thermoplastics (e.g., PBT or Nylon 66).
• Contacts: Made from copper alloy, with tin, gold, or silver plating for improved conductivity and corrosion resistance.
• IDC (Insulation Displacement) & Crimp Termination Options: Allows for fast and secure wire connections.
• Surface Mount & Through-Hole PCB Options: Available in both THT (through-hole) and SMD (surface-mount)configurations.

2. Manufacturing Process

1. a) Contact Stamping & Plating

• Stamped terminals are made from phosphor bronze or brass, ensuring mechanical strength.
• Plating is applied (tin, gold, or silver) to improve electrical conductivity and corrosion resistance.

1. b) Injection Molding (Connector Housing)

• Thermoplastic materials are injection-molded into precise housing shapes with built-in keying features.
• The housings are designed to withstand high temperatures and mechanical stress.

1. c) Terminal Assembly & Wire Termination

• Crimp-type connectors: Terminals are crimped onto wires and inserted into the housing until they lock securely.
• IDC (Insulation Displacement) versions: Wires are pushed into insulation displacement slots, eliminating the need for stripping.
• Board-mount versions: Terminals are either soldered into through-hole PCB pads or mounted using surface-mount techniques.

1. d) Testing & Quality Control

• Electrical Testing: Ensures proper continuity, insulation resistance, and voltage ratings.
• Mechanical Testing: Verifies retention force, mating/unmating cycles, and durability.
• Environmental Testing: Simulates vibration, thermal cycling, humidity exposure, and chemical resistance.

3. Applications of 396 Series Connectors

• Automotive Electronics (e.g., power distribution modules, lighting systems, engine control units)
• Industrial Equipment (e.g., motor controllers, automation systems, power supplies)
• Home Appliances (e.g., HVAC systems, washing machines, refrigerators)
• LED & Lighting Systems
• Power & Signal Connectivity in Telecommunications & Networking Devices