We are having some failures on RJ45 connectors at 2nd BI cycle. On Failure analysis, our findings indicate a poor design and workmanship at the CM. The problems is occuring at the juncture of solder joint of the coil winding on to the small Circuit card assembly. On close examination we understand the CM is doing multiple bends of the wire, which are being mechanical stressed to start with and after handling / shipping and burning we are seeing 0.5 to 1% fall out at burn-in. The CM is addressing by changing the packaging design and process / methodology of putting these to gether and adding another vib test before Temp cycling of the connectors before assembly. The question I have is - we have WIP of a number of units, which we think would need some potting material to reduce the probability of the defects going to the customer. The connectors are already assembled on the board and there is a small hole, through which we could inject some goop/potting material. I am looking for a material, which has the right amount of viscocity to be injected with a syring needle through a 2 x 5 mm hole and not bleed out through the pores/orifices of the connector to the assembly AND which could cure at less than 100 C in 10-15 minutes. Any ideas as to what material would be suitable for this application. Any lead would be helpfull thanks Sri --------------------------------------------------- Technet Mail List provided as a service by IPC using LISTSERV 1.8e To unsubscribe, send a message to [log in to unmask] with following text in the BODY (NOT the subject field): SIGNOFF Technet To temporarily halt or (re-start) delivery of Technet send e-mail to [log in to unmask]: SET Technet NOMAIL or (MAIL) To receive ONE mailing per day of all the posts: send e-mail to [log in to unmask]: SET Technet Digest Search the archives of previous posts at: http://listserv.ipc.org/archives Please visit IPC web site http://www.ipc.org/contentpage.asp?Pageid=4.3.16 for additional information, or contact Keach Sasamori at [log in to unmask] or 847-615-7100 ext.2815 -----------------------------------------------------