Gents/ladies

 I have been presented with a new product that gives me some concerns.   
The problem (as I see it) is as follows:
 
 We have a PCB which is attached to ten or so pins on a mounting base.   
The PCB is standard 1.6mm FR4, about 150mm square. Its ONLY mechanical   
support comes from sitting vertically on the joints discussed below. The   
pins are pretty large from a thermal mass point of view (large amount of   
copper at the other end of the pin, basically a spring clip).
 Now in itself this may not sound odd, and its a little difficult to   
explain the problem, but here goes. the pins are presented to the PCB   
sideways on (the side being approx. 1mm thick). The PCB has no inner   
layers and is only populated on one side (PTH and SMD). The pin is   
presented into a slot in the board which has pad surrounding it on both   
sides. the slot is not plated, it is bare FR4. The pin projects onto the   
pads by approx. half mm. This is then soldered (by hand) to both pads,   
the resulting joint looks poor to me with signs of crabby wetting between   
the pad and the pin (possibly due to the large thermal mass of the pin).   
Mechanically I think this joint is a dog (some modules only have pad on   
one side of the PCB!). The unit will be exposed to daily thermal cycling   
 (it is exposed outdoors) as well as heavy vibration (railway Trackside,   
with the PCB held upright ontop of the pins). any one share my concerns,   
maybe recommend a good test/sectioning house to explore this.

Oh and Ps this is safety critical kit believe it or not


Ian Squires

Production Engineering Manager
Redifon MEL, Crawley, UK
Tel: 44 (0) 1293 466300  xT 2425

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Ian Squires  [log in to unmask]
http://www.rmel.com   Tel: +44 (0)1293 446300

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