Excessive resistance directly affects conductivity, leading to abnormal equipment operation.
Industry technicians indicate that the core function of Conductive tape lies in achieving stable conductivity. If the resistance is too high, it will directly lead to poor contact and restricted current transmission. This may cause problems such as unstable signals, screen flickering, touch failure, and even complete equipment failure, seriously affecting user experience and the stability of the final product.
Accelerated thermal aging and shortened product lifespan
Excessive resistance can also lead to local current concentration, resulting in abnormal heating. Long-term exposure to high temperatures will cause the conductive tape and surrounding materials to age, deform, and carbonize. This not only shortens its own service life but also may cause irreversible damage to core components such as circuit boards and display modules, increasing the risk of system failure.
Increased Power Consumption, Affecting Overall Energy Efficiency and Battery Life
In new energy, battery modules, and mobile terminal products, high resistance in zebra connectors can directly cause additional energy loss, affecting the overall energy efficiency ratio and leading to increased power consumption and reduced battery life, which runs counter to the current development trend of green energy saving and low power consumption.
Potential Safety Risks in Severe Cases
CMAI quality engineers point out that in high-current applications, excessively high resistance in zebra connectors can lead to localized overheating, insulation material failure, and even short circuits or fires. This is particularly dangerous in fields such as medical equipment, new energy vehicles, and power equipment, and must be taken very seriously.
Complex Causes, Raw Materials and Processes are Key Factors
Industry analysis suggests that abnormally high resistance in zebra connectors is mainly related to the following factors:
- Insufficient or uneven distribution of conductive filler;
- Unstable vulcanization process, resulting in incomplete formation of the conductive network;
- Poor mold precision and unreasonable compression ratio；
- Improper storage environment, causing material performance degradation.
Expert Recommendations: Control Quality from the Source to Avoid Hidden Risks
Regarding the above issues, industry experts recommend that relevant companies strictly control the resistance index of zebra connectors from multiple dimensions, including raw Material Selection, production process control, factory testing, and customer verification. In particular, they should strengthen incoming material inspection and reliability testing to avoid major accidents caused by “small components.”
Meanwhile, end-user manufacturers should also fully consider the resistance redundancy design and compression ratio matching of zebra connectors during the product design phase to ensure stable and reliable conductivity under complex operating conditions.
Conclusion
Although it is of a small size, the zebra connectors plays a crucial role in conductivity and connection. Excessive resistance not only affects product performance but also may pose safety risks. In the current field of electronic manufacturing, reliability and safety are of utmost importance. Therefore, the resistance control of the zebra connector is no longer an optional aspect but a necessary requirement.
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City: ShenZhen, 518038
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