Mechanical load bearing solder (Sansa Clip Plus)

[mouse_]

I'm no engineer but please, hardware designers, stop using load bearing solder.

I saw a Sansa Clip Plus going on eBay for cheap so I decided to snag it, as this mp3 player is known for having one of the best DACs (even compared to iPod Classic) as well as community software support (Works remarkably well with Rockbox, which is Linux for mp3 players, providing useful features such as FLAC playback).

First issue was volume down didn't work. Volume up was clicky and functional but volume down had no click. So I pop it open and notice the button is entirely missing. I prod around the device and the button module falls out, apparently stuck to the adhesive on the battery. Solder it back into place and the problem becomes clear; the button has no backstop, when you press the volume keys, all the tension is exerted directly onto the button's solder joints at a 90° angle. Oh well, at least it's fixed, for now. Testing other features and notice the headphone jack drops out when the port is jostled. Further inspection reveals that the tensioner pin that locks the 3.5mm jack into place at the tip is also soldered directly onto the board at 90°, meaning any time headphones are plugged in, it is putting constant tension on the solder joint. After cleaning and applying some fresh solder to all the connections, the device is working well.

[chrisjj]

> Rockbox, which is Linux for mp3 players

We wish!

> providing useful features such as FLAC playback

Agreed.

> Solder it back into place and the problem becomes clear; the button has no backstop, when you press the volume keys, all the tension is exerted directly onto the button's solder joints at a 90° angle.

Worse I find is when you can't just solder it back because the break is not between solder and copper plate, but between copper plate and substrate.

Well done for the restoration.

[mouse_ → chrisjj]

> Rockbox is a free and open-source software replacement ... with an original kernel.

I could have sworn it was some ridiculously trimmed down Linux kernel, similar to DS Linux running on its 4mb ram. Guess not! Fun stuff.

[RetroTechie]

Solder always bears load. It just varies how much, where, when and how (angles, bending/twisting vs. pulling etc).

This is (mostly) a parts & pcb design issue. Sometimes it's the solder(ing) itself.

So, designers of this device did a poor job. And/or picked crappy parts to stick on their board. News at 11...

[brokenmachine]

I love my Sansa Clip Plus, but I'm worried that I won't be able to find a replacement when it finally dies (especially after reading this post).

Does anyone know of another mp3 player with a similar form factor?

[1970-01-01 → brokenmachine]

SanDisk makes a similar device, the clip sport.

[mistyvales]

I forgot I still have one of these in a box somewhere. I assume the battery is long dead.. but I should load rockbox on it and see how that works.

[the__alchemist]

Are these the electronic connections, or large through hole mechanical ones? I think if you have one of the large mechanical pins, with loads of solder "gluing" it in place, it can be OK. Had to tell without a picture.

Coaxial ports (SMA, BNC) etc will usually work this way, and these connections are sturdy. Obviously SMT soldering shouldn't be used for anything that applies a significant amount of force. Or, look at USB-C ports: They come in various confs, but the SMT ones (for electrical connections) will usually have 4 circular and/or oval mechanical pins which are sturdy enough.

[mouse_ → the__alchemist]

Surface mount. Truly harrowing stuff.