Car Headlight Socket Types

A2002-QA2022 :2.00mm pitch car headlight bulb connector

A2002-QA2022 Series (Compatible with PHB/HY Series)

HY/PHB refers to a class of 2.0mm-pitch board-to-board or wire-to-board connectors commonly used for internal connections in electronic devices.

"Secondary locking" refers to a mechanism that provides dual securing via a mechanical latch structure after the connector body is inserted, thereby enhancing vibration resistance and connection reliability.

Pitch and Pin Count: Featuring a standardized 2.00mm pitch, these connectors support pin counts ranging from 02 to 16, flexibly meeting signal and power transmission requirements for 2 to 16 circuits.

 

Key Advantages

Secondary Lock Secures Every Crimp Terminal

The A2002-QA2022 housing locks each terminal after primary insertion. Harness pulling, road vibration and repeated lamp servicing cannot move a terminal backward or leave a circuit partially engaged.

Four-Sided Enclosed Terminal with Double-Sided Contact

The terminal surrounds the mating pin on four sides and maintains two electrical contact surfaces. Vibration and small alignment changes do not concentrate the current path on one contact point, preserving continuity inside the headlight module.

Applicable Standards

Automotive-grade standards such as USCAR2.0 and QC/T1067-2017.

This connector is specifically designed for automotive LED lighting modules and strictly complies with automotive standards such as USCAR 2.0 and QC/T1067-2017. It provides a stable connection for various LED lighting systems, including automotive headlights, taillights, and daytime running lights.

The product features a secondary locking mechanism to prevent disconnection and fully enclosed terminals on all four sides. With dual-sided contact between the pins and terminals, combined with an external hook interlock structure, it effectively withstands vibration and shock during vehicle operation, ensuring high retention force and contact stability.

Designed with a 2.0mm pitch, it supports a rated current of 2A AC/DC and a rated voltage of 250V AC/DC. insulation resistance of ≥100 MΩ, contact resistance of ≤25 mΩ, and a withstand voltage of up to 1000 V AC/minute. It operates reliably in a wide temperature range of -40°C to +105°C and is compatible with AWG #22–24 wire gauges, providing safe, stable, and long-lasting electrical connection assurance for automotive LED lighting systems.

Jiankun's production process strictly adheres to professional control standards for electronics manufacturing. The workflow is divided into three core stages: Front-end Process, Mid-end Process & Quality Control, and Back-end Process (Warehousing and Delivery). The details are as follows:

Front-end Process: Component Formation

1. Terminal Stamping
Using high-purity copper strips as the raw material, terminal blanks are formed through cold pressing using high-speed precision stamping equipment. We strictly control the structural accuracy and mechanical strength of the terminals, laying a solid foundation for subsequent electrical connection performance.

2. Terminal Plating
Surface treatments such as Gold, Tin, or Nickel plating are completed by qualified external suppliers. These treatments enhance the terminals' electrical conductivity, oxidation resistance, and wear resistance (mating cycle life), ensuring compliance with industry environmental and reliability requirements, such as RoHS and REACH.

3. Housing Injection Molding
Engineering plastic granules (such as PA66 and LCP) are melted at high temperatures and injected into molds using precision injection molding machines to form the connector housings. This process ensures the dimensional stability, insulation properties, and heat resistance of the housings.

Mid-end Process & Quality Control

1. Automated Assembly
Using high-speed pin insertion (stitching) equipment, the plated terminals are precisely inserted and locked into the injected housings. This forms the final electrical connection structure of the connector, with assembly accuracy guaranteed throughout the process by a vision positioning system.

2. CCD Visual Inspection
A high-resolution CCD visual inspection system is utilized to automatically detect cosmetic defects (such as terminal deformation or housing flashes) and dimensional accuracy (such as terminal alignment deviation). This automated screening process achieves a detection precision of up to ±0.01mm.

3. Tape and Reel Packaging
Qualified products are packaged using carrier and cover tapes (Tape and Reel). This meets the requirements for SMT (Surface Mount Technology) automated pick-and-place processes used by downstream customers while effectively protecting products from damage during transportation and storage.

4. Final 100% Inspection
A combined inspection method of "Manual Visual Inspection + Electrical Performance Testing" is conducted to verify core electrical indicators, including continuity, withstanding voltage, and insulation resistance. This ensures that all products comply with industry quality standards such as IATF16949.

Back-end Process: Warehousing and Delivery

1. Batch Warehousing Management
Qualified products are scanned into the WMS (Warehouse Management System) for storage. This system enables full production batch traceability, dynamic inventory control, and strict FIFO (First-In, First-Out) management.

2. Order Delivery & Shipment
Picking and preparation are completed based on customer order requirements. Shipments are arranged through the logistics system, accompanied by batch traceability reports and COCs (Certificate of Conformance) to ensure timely delivery and full quality traceability.

Jiankun Connector's core production base is guided by the IATF16949 Automotive Quality Management System and the ISO9001 General Quality Standards. Centering on the performance demands for compact structures and high-reliability connections, the facility has constructed a full-process autonomous production chain covering "raw material processing - component molding - finished product assembly - quality inspection." Through specialized workshop zoning, precise division of labor, and empowerment via intelligent equipment, we achieve controllable quality and efficiency across all links, providing a robust hardware foundation for high-end scenarios in automotive, medical, digital, and other sectors.

Injection Molding Workshop: High-Precision Automated Molding for Stable Miniature Components

As the core unit for the "plastic raw material branch," the injection molding workshop focuses on the precision molding of connector miniature housings, internal locks, and other plastic structural parts. The entire process aligns with the design requirements for compactness and high rigidity:

Equipment & Process Control: Utilizing advanced injection molding machines to ensure dimensional stability.

Process Quality Verification: Continuous monitoring of molding parameters to prevent defects.

Stamping Workshop: Precision Copper Strip Processing for Core Terminal Performance

Acting as the key processing area for the "copper strip raw material branch," the stamping workshop focuses on the precision stamping of miniature terminals. This provides the core material guarantee for the product's electrical performance, specifically low contact resistance and high connection stability:

Equipment & Material Configuration: High-speed precision stamping equipment paired with high-purity alloys.

Process Linkage Assurance: Seamless transition from stamping to surface treatment to maintain terminal integrity.

Assembly Workshops I & II: Automated Integrated Assembly for Closed-Loop Quality Control

Assembly Workshops I and II focus on core integration processes. Through the layout of multiple intelligent automated production lines, they receive qualified components from the stamping and injection stages to complete terminal insertion, component integration, and other core workflows while simultaneously performing precise verification:

Automated Precision Assembly: High-speed, high-accuracy assembly through robotic integration.

Integrated On-line Detection: Real-time visual and electrical testing to ensure zero-defect output.

Full-Process Autonomous Layout: Dual Guarantee of Efficiency and Quality

The production base is built around a full-process autonomous layout, breaking down barriers between raw material processing, component molding, and finished product assembly. Each workshop utilizes a digital management system to realize production data interconnectivity, allowing for the precise traceability of every raw material batch, equipment parameter, and inspection data point. This integrated layout not only shortens production lead times to meet the bulk delivery needs of diverse clients but also constructs a comprehensive, controllable quality system through process standardization and continuous inspection.

1. Standardized Packaging Design
Jiankun (JKUN) adopts industry-standard packaging solutions. Products are neatly organized into specialized cartons according to their specifications. Once packed, they are secured onto pallets for uniform stability. This approach ensures tidy stacking and compatibility with forklift loading and unloading processes, significantly enhancing the convenience of warehousing and transit operations.

2. Standardized Storage Requirements
Products must be stored in their original, intact packaging throughout the entire process. The storage environment should be a clean and dry warehouse. It is highly recommended to prioritize areas that are protected from light, have minimal temperature and humidity fluctuations, and maintain low humidity levels. Additionally, avoid subjecting the packaging to external pressure or collisions to prevent damage that could compromise product performance.

3. Flexible Transportation Options
To meet diverse order requirements and varying logistics coverage, we offer a wide range of transportation modes. These include road transport (trucking), international express services (such as UPS, TNT, FedEx, EMS, DHL), air freight, and sea freight. Shipping methods can be flexibly adapted based on the actual application scenario.

4. Transportation and Handling Precautions

• During transit, it is critical to prevent the packaging from coming into contact with sharp objects and to avoid severe impacts. This ensures the integrity of the packaging and preserves product quality.
• Under normal transportation and standard handling conditions, this product does not pose any health hazards. However, significant attention must still be paid to loading and unloading safety to avoid improper or non-compliant operations.
• Packaging materials must be disposed of properly and must not be discarded randomly, ensuring compliance with both environmental protection requirements and operational standards.

Our company's quality control system is built around internationally recognized certification standards, establishing a three-pronged quality assurance model that integrates "system certification endorsement, end-to-end process control, and full lifecycle traceability." This ensures stable and reliable product quality, compliance with regulatory requirements, and comprehensive adherence to market access criteria and application standards across global markets.

A quality assurance system empowered by authoritative certification

The company has established a multi-tiered compliance system covering quality, environmental, and industry-specific domains. Supported by both standardized management systems and product certifications, this framework lays a solid foundation for ensuring product quality：

• IATF16949 Automotive Industry Quality Management System Certification
• ISO9001 Quality Management System Certification
• ISO14001 Environment Management System Certification
• UL/CUL Product Safety Certification
• CE Product Compliance Certification

Comprehensive, closed-loop quality control measures across the entire process

Leveraging an authoritative certification system, the company has established a seamless, end-to-end quality control mechanism covering the entire process from "incoming materials to production to finished products," ensuring the precise detection and rejection of non-conforming products：

• Material Quality Control(IQC)
• Quality Control in the Production Process(IPQC)
• Final Product Inspection(FQC)

Full Life Cycle Quality Traceability and Continuous Improvement

The company has established a unique batch identification and traceability system for its products. Through batch codes, it enables full-chain traceability of raw material sources, production equipment, process parameters, testing data, and operators, ensuring precise identification and rapid review of quality issues. In line with ISO 9001 continuous improvement requirements, the company regularly collects customer feedback and production quality data, conducts systematic data analysis and process optimization, and drives dynamic upgrades to its quality control system and product quality, thereby continuously enhancing customer satisfaction.