RJ-45 Quality Issues
Proven RJ-45 Interconnect Problems Are Affecting Signal Quality
Resulting in Poor Signal Transmission, Intermittencies, Shorts and Potential Signal Loss
The RJ-45 Is A Highly Engineered Interconnection System
CAVEAT EMPTOR.....Let The Buyer Beware
SUB-STANDARD, NON-COMPLIANT and COUNTERFEIT RJ45's coming in from the Far East
KNOW THE STANDARDS - KNOW THE SPECS - INSIST ON COMPLIANCE - KNOW YOUR SUPPLIERS
We have been inundated with emails and phone calls from around the globe from companies experiencing problems with RJ-45's. It is very disturbing to find out that many of these problems relate to the RJ-45 plug/jack NOT MEETING THE MINIMUM MECHANICAL or MATERIAL STANDARDS REGARDING GOLD PLATING, PLASTIC HOUSING MATERIAL and CONTACT DESIGN/DIMENSIONS as set forth by standards bodies such as ACTA, ASTM, EIA, FCC, IEC, IEEE, ISO, TIA and UL.
RJ-45 PROBLEM AREAS AND ISSUES HERE IS WHAT WE ARE SEEING - YOU WILL NOT BELIEVE IT
NON-COMPLIANCE - CHEATING - COST CUTTING OPERATIONS AFFECTING PRODUCT QUALITY
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In a recent study.....
OVER 50% OF ALL RJ-45 PLUGS TESTED DID NOT MEET THE MINIMUM GOLD and/or NICKEL PLATING REQUIREMENTS PER TIA, IEC and FCC SPECIFICATIONS
Specifications call out for 50 micro inches of (hard) Gold on the surface mating portions of the plug and jack over a minimum of 50 microinches of (pure) Nickel over the base metal phosphor bronze. According to the TIA and ACTA Commission, they have noted that sub-standard plugs and jacks have posed a significant problem for consumers. In particular, such plugs and jacks may be difficult to interconnect and may lack the gold plating on the contact interface needed to prevent interference. As a result, there is a TICKING TIME BOMB WITH OXIDATION, CONDUCTIVITY, CONTACT RESISTANCE AND CORROSION that may cause complete signal transmission loss or intermittent contact (that alternates rapidly between a high and low resistance), which is the worst nightmare for anyone who has to troubleshoot network equipment.
To learn more about the PROBLEMS WITH GOLD PLATING, GOLD DIFFUSION (There's No Gold On My Contacts"), GALVANIC REACTIONS BETWEEN TWO DISSIMILAR METALS and PLATING STANDARDS, PROCEDURES and BEST PRACTICES, go here:
THERE IS A DISTURBING TREND OF RJ45 PLUGS AND JACKS NOT MEETING DIMENSIONAL SPECIFICATIONS PUT FORTH BY THE TIA, IEC, ISO AND FCC ALONG WITH THE USE OF ALTERNATE MATERIALS BEING USED
This Section looks at PROPER DESIGN ELEMENTS based on STANDARDS and SPECIFICATIONS. It also highlights the importance of TOOLING DESIGN, MOLD DRAFTS, TOLERANCES and their impact on the MATEABILITY of the PLUG/JACK INTERCONNECTION....and their relationship to TARGETING and GUIDANCE.
This Section describes APPROPRIATE SURFACE CONTACT MATING AREAS for signal transmission integrity and explains Interconnect Problems that are Affecting Signal Quality.....Resulting in Poor Signal Transmission, Intermittencies, Shorts and Potential Signal Loss.
Do not take this step for granted. RJ-45 TERMINATION TOOLING IS CRITICAL TO ACHIEVE THE DESIRED ELECTRICAL PERFORMANCE of the cable assembly. This section underscores the importance of PROPER BLADE DEPTH and shows some of the problems that may arise if specs are not met.
THE SENTINEL CONNECTOR SYSTEMS ADVANTAGE
Why Not Go To The Best In The First Place?
Sentinel Connector Systems is the premier "MADE IN USA" manufacturer of RJ-45 Plugs and Jacks. As a matter of fact, their Founder was part of the original design team at Hardesty that actually built the first RJ type connector ever. We have the BOOK OF RJ.....representing over 40 years of hand written notes about the why's and dont's of manufacturing RJ-45 Interconnection Systems.
THE BOOK OF RJ (Robert J Brennan)
WE DO EVERYTHING FOR A REASON
The guys at Sentinel have OVER 250 MAN YEARS OF EXPERIENCE, HOLD 35 RJ45 RELATED PATENTS and HAVE THE ANSWERS to all of your RJ-45 related questions. We are just a phone call or email away.
THE SENTINEL CONNECTOR SYSTEMS ADVANTAGE - All of Sentinel's Plugs and Jacks are built in accordance to INDUSTRY STANDARDS & SPECIFICATIONS as set forth by governing bodies such as ACTA, ASTM, FCC, IEC, IEEE, ISO, TIA and UL. Sentinel is also a Member of the Communications Cable and Connectivity Association.....adhering to the Association's STRICT CODE OF ETHICS regarding compliance.
HOW WE DO THINGS
OUR PRODUCT DESIGN ELEMENTS - The BASIS METAL for the contacts is PHOSPHOR BRONZE. We use a very specific % along with a very tightly controlled min-max granular MICROSTRUCTURE to provide the best STIFFNESS, SPRING QUALITIES and CORROSION & WEAR RESISTANCE. The basis metal is then plated with 100 micro inches of Nickel (min plugs, 50 micro min jacks)....providing a sacrificial metal surface/barrier to PROHIBIT DIFFUSION and OBTAIN DESIRED POROSITY CHARACTERISTICS....then 50 micro inches (minimum) of 24 CARAT (hard) GOLD adhering to MIL-G-45204C, TYPE II, GRADE A specifications and Knoop Hardness requirements. During each plating operation, PROPER SURFACE ACTIVATION and CLEANSING PROCEDURES are meticulously followed to insure against any possible surface contamination and potential GALVANIC REACTIONS (reference MIL-STD-889).
All surface contact areas are ELECTROPOLISHED (versus wire brushed) creating an extremely smooth "BURR FREE" CONTACT SURFACE.
By incorporating the strict design guidelines above, Sentinel Plugs and Jacks will have a MINIMUM 1,000 CYCLE LIFE (insertions/de-insertions) before any degradation of surface contact areas and a 2,000 MINIMUM CYCLE LIFE WHEN USING SENTINEL PLUG/JACK COMBINATIONS.
OUR ENGINEERING and MANUFACTURING EXPERTISE
* Sentinel manufactures it's plastic components on Battenfeld and Cincinnati molding presses with tightly controlled tolerances and a meticulous Quality Control Program to insure Standards Compliant Parts.
* Connectors are assembled with equipment both purchased and designed/manufactured in house. Unparalleled Quality Procedures and Maintenance Programs insure that the products are assembled with consistency and reliability, plus the Equipment runs 24/7, LIGHTS OUT.
* The Quality Department utilizes equipment to test gold thickness and mechanical properties of all the connectors manufactured.
* The Engineering Department uses State of the Art CAD equipment and has a fully equipped Tool Room to support Manufacturing as well as New Product Development.
THE BOTTOM LINE - WE DO NOT CUT CORNERS.....WE USE BEST PRACTICES.....WE MEET and/or EXCEED ALL STANDARDS....WE PROVIDE THE HIGHEST QUALITY IN THE MARKETPLACE.....and best yet, WE ARE EASY TO WORK WITH and our products are MADE IN THE UNITED STATES OF AMERICA.
KNOW THE STANDARDS
KNOW THE SPECIFICATIONS
INSIST ON COMPLIANCE
KNOW YOUR SUPPLIERS