Sturdy blade-style relay terminals? - Page 1
Forum section: electronics / projects

author: Tom18991
author_rank: Contributor
timestamp: April 17, 2023, 05:43:51 pm
content: I'm working on a project that needs to plug into a socket vacated by a relay similar to the one shown. Trying to figure out what terminals to use on a PCB board that will be sturdy enough to withstand being inserted and removed from the socket. I've found a number of blade terminals like the one shown below. If I create/find the right footprint for a terminal like this, and solder it in -- is that all there is to it? Or is there some better part or technique for making those terminals structurally secure? Thanks!

author: WattsThat
author_rank: Frequent Contributor
timestamp: April 17, 2023, 06:50:51 pm
content: Are you going to build a board that has five of the 1/4 inch terminals arranged in the same format as the relay being removed? If so, how large will board be and how many total 1/4” terminals? A thicker than the usual .062/1.6mm board may be in order due to forces involved.PS: It is common to see the top side of the terminal hand soldered to the lands along with lots and lots of vias all around the long dimensions of the blade. Can probably find a board here with an example of how it is typically done for photos if needed.

author: jpanhalt
author_rank: Super Contributor
timestamp: April 17, 2023, 07:08:11 pm
content: Isn't clear what you want. As Watts said, do you want the same 1/4" terminals in the same design or will a different size spade work? If yes to the former, then the female spade terminal can be opened a tiny amount to make insertion and removal easier. If the latter, there are lots of choices. I bought a dozen different types a few years ago for making the female part of a typical Omega spade TC connector, which are about 1/8" wide. Please let us know, and I will dig out my notes.

author: tooki
author_rank: Super Contributor
timestamp: April 17, 2023, 07:15:03 pm
content: As I understand it, OP wants to make a module that plugs into an existing relay socket. If that’s the case, then I think using the solder-in spades will work just fine, since the insertion force of a relay socket isn’t as high as that of 5 standard female spade connectors.

author: ajb
author_rank: Super Contributor
timestamp: April 18, 2023, 01:43:26 am
content: Keystone make versions of those terminals with additional tab sorta things folded out to the sides that give them a slightly wider footprint for better stability:https://www.keyelco.com/category.cfm/250-6-35-Male-Tab-Quick-Fits/Vertical-Sturdi-Mount/p/401/id/877/c_id/1103One thing to note is that there are different thicknesses of those QC tabs as well as different widths. It's worth checking what size terminals you want, while thicker tabs can go in thinner receptacles they take a LOT more force to insert and remove.

author: Tom18991
author_rank: Contributor
timestamp: April 18, 2023, 02:17:23 pm
content: Thanks everyone! That pretty much answers my core question -- I mostly just wanted to make sure there wasn't some other world of relay blade mounting that I was missing. If solder blades into thick PCB boards is the basic idea, I'll just hunt for the right size pins now. And I do like those Keyelco Sturdi-mount terminals, although I wonder if it would prevent the part from settle all the way down and flush with the socket it's plugging into...?