Hi Steve - we typically use a washer type device to address the forming of
TO type device leads when this concern/question is raised. That seems to
make everyone happy.

Dave Hillman
Rockwell Collins
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On Thu, Jul 28, 2016 at 10:12 AM, Steve Gregory <[log in to unmask]> wrote:

> Hi All,
>
> We're building a board for a customer that uses a 8-lead TO-5 style relay.
> The footprint on the board requires that the leads are spread out to a
> larger diameter circle than what diameter is when they come out of the body
> at the bottom of the relay. Here's the information for one of the relays,
> there are three others that are the same style:
>
>
> http://www.digikey.com/product-search/en?lang=en&site=us&WT.z_cid=ref_findchips_standard&mpart=PRMAC-26X
>
> So we have a Simonds CLP274 lead processor with a die that matches the
> footprint on the PCB:
>
> http://stevezeva.homestead.com/Simonds_CLP274.jpg
>
> We insert the part which spreads the leads out, then step on the pedal and
> a guillotine style blade shears the leads off. I've used the prep unit
> many, many time before at previous employers without issues. The customer
> is saying that prepping the leads in this unit is damaging the relay. So
> now we are to pot the leads before prepping them with a 2-part epoxy using
> a tooling fixture as a mold for the epoxy, and the potted relay looks like
> this:
>
> http://stevezeva.homestead.com/Potted_Relay.jpg
>
> Has anybody ever heard of this Simonds unit damaging relays like this? Has
> anybody had to add potting to a relay like this? I can understand wanting
> to keep the leads coming straight out of the bottom of the body before
> making the bend to match the footprint on the board, but I think I can use
> a Bivar permanent spacer and slip it over the lead and accomplish the same
> thing. Something like this:
>
>
> https://www.google.com/url?sa=t&rct=j&q=&esrc=s&source=web&cd=2&ved=0ahUKEwiqk8zCt5bOAhWJ1IMKHebaCR8QFggxMAE&url=http%3A%2F%2Fwww.bivar.com%2Fportals%2F0%2Fproducts%2F616-070.pdf&usg=AFQjCNESVvvX6qOo_-0T94sAYNLP8AJ21Q&cad=rja
>
> Or even a nylon washer that matches the diameter of the lead pattern
> (.200") coming out of the bottom of the relay. Potting this relay is going
> to be very time consuming and there's going to be a risk of getting the
> epoxy on the leads that will ruin the solderability of the part. I'm just
> trying to understand if it is truly the Simonds prep unit causing the
> damage, and if this really is, and easier way other than potting them to
> accomplish the same thing.
>
> Thanks all!
>
> Steve Gregory
>
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