The Kynix Blog - Connectors

Warm hints: The word in this article is about 2600 words and  reading time is about 15 minutes. In this article, we will mainly introduce the classification, performance, and development trends of electrical connectors. Connectors, as key components of current or signal connections, are also an important part of the industrial system. Not only in aircraft, rockets, connectors are also used in microphones and televisions, which all come in various forms. It builds bridges between circuits or other components that act as current or signal connections. Catalogs I. What Is A Connector?II. Classification of Electrical ConnectorIII. Basic Performance of ConnectorsIV. The Basic Structure of ConnectorV. Development trend of Electronic Connector Technology in the FutureFAQ  I. What Is A Connector?  Connectors, an electro-mechanical device, generally refers to electrical connectors. That is, a device connects two active devices and transmits current or signal.(Connector)Connectors are a kind of component that electronic engineers often come into contact with. Its function is very simple: to bridge the communication between the blocked or isolated circuits in the circuit, so that the current can circulate. The connector is an indispensable part of an electronic device. If you look at the path of the current flow, you will always find one or more connectors. The form and structure of connectors vary greatly, which is depending on the object, frequency, power, environment, etc. For example, connectors for on-court lights and hard drives, and connectors for rocket ignition are very different. But no matter what kind of connector is, it should ensure that the current flowing smoothly, continuously, and reliably. In general terms, the connector is not just used to connected current. With the rapid development of optoelectronic technology, the carrier of signal transmission in optical fiber system is light, glass and plastic also replaced the wire in the ordinary circuit. However, connectors are also used in optical signal pathways, which act the same as circuit connectors.   (Connector)The birth of the connector came from the manufacturing technology of fighter planes. Aircraft in battle had to be refueled and repaired on the ground, and the duration of stay on the ground was an important factor in the victory or defeat of a battle. Therefore, in World War II, the US authorities are determined to reduce ground maintenance time and increase the combat time for fighter jets. They first unitized the various control instruments and machine parts, and then connect them with the connectors to form a complete system. During repair, the faulty units are taken apart and the new units are replaced and the plane will soon be able to fly into combat. After the war, AT-T Bell Labs successfully developed the Bell telephone system, followed by the rise of industries such as computers, communications, and so on, which gives more opportunities for the development of connectors derived from stand-alone technology. II. Classification of Electrical Connector Due to the increasing diversity of connectors and the emergence of new structures and applications, it is difficult to classify and name the connectors by using a fixed pattern. Here we will discuss the classification of connectors on different basis.   1. By nature of useExternal connectors (for external housing), internal connectors (for internal housing). 2. By level of connectors> Level 1  DEVICE TO PACKING : Refers to the connection between IC chips and pins(Level 1)> Level 2 COMPONENT LEAD TO CIRCCUITRY: Refers to the connection between components and PC boards(Level 2)> Level 3 BOARD To BOARD: Refers to the interconnection of PC boards(Level 3)> Level 4 SUBASSEMBLY TO SUBASSEMBLY: Refers to the connection of subsystems to subsystems(Level 4)> Level 5 SUBASSEMBLY TO I/O PORT: Refers to the connection between subsystems to I/O port(Level 5)> Level 6 SYSTEM TO SYSTEM: Refers to the connection between system to system(Level 6) 3. By Processing MethodCrimp Type, I.D.C Type, Solder Type, Z.I.F Type 4. By Usage ModeWire to Board connector, Board to Board Connectors, Wire to Wire connector, socket, Input / output connector 5. By FormsPCB board connector, Flat cable connector, Coaxial cable connector, Embedded connector, Axial connector, Circular connector, Angular connector, Connectors for printed wiring boards 6. By StructureGeneral connector, Waterproof connector, Environment-resistant connector, Airtight connector, Refractory connector 7. By Operating FrequencyLow frequency connector, High frequency connector(Bounded at 3MHz) 8. By the Universality and Related Technical StandardsLow frequency circular connector, Rectangular connector, Printed circuit connector, RF connector, Fibre connector  (This video illustrates various types of electrical connectors or "Terminals" how they are used and how to connect them.) III. Basic Performance of Connectors The basic performance of the connector can be divided into three major categories: mechanical performance, electrical performance and environmental performance. 1. Mechanical performanceAs far as the connection function is concerned, the insertion force is an important mechanical performance. Insertion force is divided into insertion force and withdrawal force (withdrawal force is also called separating force), whose requirements are different. The maximum insertion force and the minimum separating force are stipulated in relevant standards, which indicates that the insertion force should be small from the application (thus having the structure of low insertion force LIF and no insertion force ZIF), but if the separating force is too small, the contact reliability will be affected. The insertion force and mechanical life of the connectors are related to the coating quality (sliding friction coefficient) of the contact structure (positive pressure) and the alignment accuracy (alignability). 2. Electrical performanceThe main electrical performance of connectors include contact resistance, insulation resistance and dielectric strength. > Contact resistance: High quality electrical connectors should have low and stable contact resistance. The contact resistance of connectors ranges from a few mOhms to tens of mOhms. > Insulation resistance: Insulation resistance is an index of insulation performance between contacts of electrical connectors and between contacts and shells, and its order of magnitude ranges from hundreds of megohms to thousands of megohms. > Dielectric strength: Also called withstand voltage or dielectric voltage, which refers to the ability to withstand rated test voltage between connector contacts or between contacts and housing. > Other electrical performanceElectromagnetic interference (EMI) leakage attenuation is used to evaluate the shielding effect of electromagnetic interference (EMI) of connectors, which is generally measured in the frequency range of 100MHz~10GHz. For RF coaxial connectors, there are also electrical indexes such as characteristic impedance, insertion loss, reflection coefficient, VSWR, etc. Because of the development of digital technology, in order to connect and transmit high-speed digital pulse signal, a new type of connectors, i.e. high-speed signal connectors, have emerged. Correspondingly, in addition to the characteristic impedance, some new electrical indexes have appeared, such as crosstalk, delay skew and so on. 3. Environmental performanceCommon environmental performance includes temperature resistance, moisture resistance, salt spray resistance, vibration and shock resistance, etc. > Temperature resistanceAt present, the maximum operating temperature of connectors is 200℃ (except for a few special high-temperature connectors), and the lowest temperature is-65 ℃). As the current produces heat at the point of contact, resulting in temperature rise when the connector is working. Therefore, it is generally believed that the working temperature should be equal to the sum of ambient temperature and contact temperature rise. In some specifications, the maximum allowable temperature rise for connectors at rated operating currents is classified. > Moisture resistanceThe invasion of moisture will affect the insulation performance of connectors and corrode the metal parts. The constant hygrothermal test conditions are as follows: relative humidity 90%~95% (according to the product specification, up to 98 ℃), temperature 40 ±20 ℃, the test time is prescribed by the product, minimum 96 hours.  > Salt spray resistanceWhen the connector works in an environment containing moisture and salt, its metal structure and contact surface treatment layer may produce electrochemical corrosion, which will affect the physical and electrical performance of the connector. In order to evaluate the ability of electrical connectors to withstand this environment, a salt spray test was prescribed. The connector is suspended in a temperature-controlled test box and ejected with compressed air with a specified concentration of sodium chloride solution to form a salt fog atmosphere. The exposure time is prescribed by the product specification for at least 48 hours. > Vibration and shock resistance They are the important performance of electrical connectors, especially in special application environments such as aviation and aerospace, rail, and road transport. It is an important index to test the mechanical structure of the electrical connector and the reliability of electrical contact. It is clearly stipulated in the relevant test methods. The peak acceleration, duration, impulse waveform, and the time of electrical continuity interruption should be specified in the impact test. > Other environmental performanceAccording to the operation requirements, the other environmental performance of electrical connectors includes leak proofness(Air leakage, liquid pressure), liquid impregnation(the ability of a specific liquid to resist the evil habit) and low pressure, etc.   IV. The Basic Structure of Connector The basic structure of connector includes: contacts, insulator, housing, accessories. (Basic Structure)1. ContactsContact is the core part of the connector to complete the function of an electrical connection. the contact pair is usually made up of positive contact and negative contact, which is electrically connected through the insertion of negative and positive contacts.Positive contacts are rigid parts with cylindrical shapes (round pins), Square column shape (square pins), or flat shapes (inserts). Positive contacts are generally made of brass and phosphor bronze. 2. InsulatorThe insulator, also known as the base or mounting panel (insert), is used to arrange the contacts according to the required position and spacing, and to ensure the insulation between the contacts or between the contacts and the housing. Good insulation resistance, voltage resistance, and processability are the basic requirements of insulator selection. 3. HousingHousing, also called a shell, is the cover of connectors. It provides mechanical protection for built-in insulating mounting panels and pins, and alignment when plugs and sockets are plugged in, thereby securing connectors to the device. 4. AccessoriesAccessories are divided into structural accessories and mounting accessories. Structural accessories are such as rand, positioning keys, dowel pins, guide pins, connecting rings, cable clamps, sealing rings, gaskets, etc. Mounting accessories are blots, nuts, screws, spring coil, etc. Coils, etc. Most of the accessories have standard parts and general parts.  V. Development Trend of Electronic Connector Technology in the Future Connectors, as a key component of current or signal connections, are also an important part of the industrial system. With the rapid development of personal mobile terminals, home intelligent appliances, information and communication industry, transportation and new energy industry, aerospace technology, artificial intelligence, medical electronic devices, and other fields, there are higher requirements for connectors in function, appearance, performance, and use environment. 1. Development trend of miniaturization and integrationIn order to meet the requirements of portable, digital and multifunctional electronic machines, as well as production and assembly automation, electronic connectors must adjust their product structure. Products are developed to small size, low height, narrow distance, multi-function, long life, surface installation, and other directions. Miniaturization means that the center spacing of electronic connectors is smaller, and the high density is the realization of a large core number. The miniaturization of consumer electronics requires miniaturization of components, thinness, and high performance, which also promotes the development of connector products towards miniaturization and small spacing. The miniaturization of components requires higher technical requirements. This requires a strong industrial mold base to effectively support. 2. Development trend of intellectualizationToday is a world of rapid information, no matter what kind of information or technology, people are demanding more and more. With the rapid development of information and communication data, wireless interconnection has come into our daily life. From the application of smartphones, smart wearable, UAVs, unmanned reality, intelligent robot, and so on, the development of electronic connector with IC chip and control circuit is an inevitable trend. This will enable the electronic connector to master the use of electronic devices more intelligently and improve the performance of the connector itself to achieve intelligent wireless bridging. 3. Development trend of high performanceHigh-speed transmission means that modern computers, information technology, and networking technology require the time scale rate of signal transmission to reach the MHz band and pulse time to sub-millisecond, so a high-speed transmission electronic connector (connector) is required.  In order to adapt to the development of millimeter-wave technology, RF coaxial electronic connector has entered the millimeter-wave working frequency band. High current is also an important development direction of many electronic connectors. In the modern high-tech industry, there are many connectors that are used under extreme environmental conditions.  Under the conditions of ultra-high temperature, low temperature, vibration, dampness, and heat, corrosive environment, electronic connectors can be used effectively and normally. This makes connectors more demanding in the selection of raw materials, structural design, processing techniques, new high-temperature-resistant materials, and the new electroplating coating processes.  FAQ 1. What are the 3 types of connectors?Electrical connectors are classified into three types based on their termination ends: board-to-board connectors, cable/wire-to-cable/wire connectors, and cable/wire-to-board connectors. Six levels of interconnection are normally seen in electrical connectors. 2. What are electrical connectors called?Twist-on connectors are also known as wire nuts, wire connectors, cone connectors, or thimble connectors. 3. What is the use of electrical connector?An electrical connector is an electromechanical device used to join electrical conductors and create an electrical circuit. Most electrical connectors have a gender – i.e. the male component, called a plug, connects to the female component, or socket. 4. Which tool is used to attach connectors to wires?PLIERS. ⟹Pliers are tools for gripping and cutting wires or connectors. 5. How many types of electrical connections are there?There are three categories of electrical connectors: light-duty, medium-duty, and heavy-duty. Each category heading refers to how much voltage the connector can handle. A light-duty electrical power connector can carry up to 250 volts (V) of a low current. 6. What are different types of connectors?Types of Connectors:Box-to-box or input/output.Wire-to-board.Chip-to-package.Package-to-board.PC board-to-board. 7. What is a connector?A connector is essentially the social equivalent of a computer network hub. Connectors usually know people across an array of social, cultural, professional, and economic circles, and make a habit of introducing people who work or live in different circles. 8. Why do we use connectors?Connectors are an important tool for writing proficiently in English. Their purpose is to join information together within a sentence. Using connectors correctly will help ensure the meaning of your sentences are clear for readers to understand. 9. How many types of electrical connections are there? There are three categories of electrical connectors: light-duty, medium-duty, and heavy-duty. Each category heading refers to how much voltage the connector can handle. A light-duty electrical power connector can carry up to 250 volts (V) of a low current. 10.What is the most popular type of connector?In the USA for networking and audio/video, the three most popular styles are LC, SC, and ST. LC and SC tend to be the most commonly used styles. Today, ST connectors are seeing more limited usage. You May Also Like:As the Development of Technology ,Connectors Should be Linghter,Smaller and SmarterHeavy Duty Connectors from TE Connectivity Offer A Range of Connectivity Solutions for InstallationHybrid Connector Combines Floating Contact Alignment with High Speed Transmission

 As the technology landscape continues to evolve and becomes ever mor complexs,more and more traditional electronic components are having to evolve to support new capabilities expecially connectors. Even emerging technologies, whether that’s artificial intelligence, the use of big data analytics, or smart wearable devices and drones, are being appropriated by the world’s military in order to improve the effectiveness and capabilities of their armed forces. Connectors may not be considered the most technological of products, but they haven’t been immune to the mega trends sweeping through many industries, not least the need to supply components that are smaller but also lighter and smarter.The changes are significant with product performance in the military space and electrical integrity having a huge impact on connector systems and their design, whether in terms of the equipment being used by soldiers, rugged displays, communications equipment or in vehicle electronics. Bob Stanton--technology director at Omnetics said: Today’s newer electronic instruments can neither afford the space or the weight required by older cabling and connector systems.High performance product is required and it needs to offer customers space and weight benefits but without impacting on performance, reliability or functionality.”  A growing list of connector suppliers are working on replacing two or three connectors with one miniature, dense multi-functional connector, for example, and that is having an impact on the kinds of cables people are looking to choose. ODU, a supplier of connector system's, has been working on developing connectors suitable for use with multiple interfaces that will be connecting the soldier of the future with their weapons and communications as well as with military vehicles and, according to the company’s managing director, Nick Harper, has been focused on developing one connector family capable of meeting the requirements for every application. (ODU has been heavily involved with supplying over 100,000 helmet connectors as part of the Ministry of Defence's Bowman programme.) While engineers are looking to supply smaller, more compact, connectors they have to also ensure that they are able to withstand temperature extremes, vibration, and be able to operate in an environment that might be sandy, wet or dirty – all of which could compromise the integrity of the connector. New surface treatments and technologies are being developed specifically to address the extreme environmental conditions expected in the military space. Take an example, connector manufacturer, LEMO, has developed NiCorAl a corrosion resistant conductive surface treatment that offers an alternative to Cadmium. Miniaturisation “New technologies are driving continuous miniaturisation of electronic equipment for communications, computing, surveillance, sensing and navigation,” according to Stanton. “Whether soldier-worn or on-board a UAV or UGV, small size and light weight are demanded – but no performance compromises can ever be accepted.” Many of the older military specification models are becoming outdated in the face of growing demands for micro- and nano-sized connectors that are needed to address the requirements of higher-technology electronics. “Trusted military connectors like MIL-DTL-24308 D-subs are being superseded by smaller, lighter alternatives like 83513 and 32139 Micro- or Nano-Ds,” explains Stanton. “Smaller can never mean weaker, though,” he warns. “Although they have very fine pitch (0.64mm for the Nano-Ds), they must be able to withstand environmental hazards like extremes of heat and cold and exposure to corrosive chemicals.”  In order to address this, Omnetics uses open-ended beryllium-copper pins, which are shaped to maintain four continuous points of contact and are tempered for continuous spring force.  “These have actually exceeded 2000 mate/de-mate cycles in testing, and the design gives extra travel in compression and expansion to ensure continuous electrical contact even during extremely harsh vibration,”  Stanton continues, “Sockets are copper-alloy, and designed to increase contact pressure as they expand at higher ambient temperatures. When cold, the socket contracts without over-stressing the spring. Contacts are nickel/gold plated after forming, meeting ASTM B488 Type II, giving high corrosion resistance.” Soldiers can be under huge pressure in action, so speed and convenience are also critical. Stanton explained that at Omnetics we have designed innovative latching Nano-D families that connect securely without fiddly jackscrews, and which pass the stringent MIL-DTL-32139 shock and vibration specifications. Military connectors are also having to contend with another important trend and that is the dramatic increase in the amount of data that is being routed between devices and people. More data requires more sensors and where data is time critical and where interference is unacceptable connectors that are smaller and more rugged are required. Technological Arms Race “Keeping the technological upper hand is critical to ensure military success,” explained Stanton. “Today's military forces need to maintain their superiority in unfamiliar environments from mountainous deserts to urban areas and, accordingly, soldiers need to be quick on their feet, and unmanned aerial and ground vehicles are increasingly in demand for dangerous missions, close to the enemy.”  Ben Green, Head of New Business at Harwin agree with it .“A key method for protecting frontline troops and ensuring that lives are not placed into unnecessarily dangerous situations is through greater use of smart technology. The interest in unmanned aerial vehicles (UAVs) and unmanned ground vehicles (UGVs) has grown significantly, as a result.” UAVs and UGVs enable the military to undertake a number of operations - including detailed surveillance, the transportation of vital supplies and even recovery missions - without placing service personnel at risk. “These types of vehicles have to rely on the incorporation of sophisticated electronic circuitry and, in turn, the support of high reliability cabling/interconnects - so that the power needed to drive the motors for propulsion purposes and data from an array of different sensors to allow timely manoeuvring can be delivered,” Green says. “The constituent components all need to be compact and light in order to deal with space and weight constraints, so that less impact is placed on their limited energy reserves and the vehicles can cover longer distances before they have to return.” These trends are combining to drive continuous miniaturisation of electronic equipment for communications, computing, surveillance, sensing and navigation Green says. “Whether soldier-worn or on-board a UAV or UGV, small size and light weight are demanded.” To address these demands, defence agencies and their military contractors need to be able to collaborate with suppliers who can provide them with robust, high performance components in small form factors. “The connectors specified as part of UAV/UGV design and development activity, for example, as with any other military-related application, need to possess elevated levels of reliability, as well as exhibiting high degrees resilience to electro-magnetic interference (EMI),” Green contends. “Dealing with all these different aspects is clearly challenging, so engaging with the right supplier is absolutely critical,” he concludes. But there is another reason why equipment needs to be compact, lightweight, and technically advanced, according to Stanton. “Today's arms races increasingly pit professional armies against militias that are adept at harnessing powerful consumer technologies, whether that’s smartphones, mobile data, GPS or quadcopters. “Overcoming these challenges demands smart thinking about even the finest of details – and that includes the connector.”   

Global connectivity and sensor provider, TE Connectivity (TE), offers a range of connectivity solutions for diverse motor types. With trends in connectivity toward more miniaturisation, reduced installation times, improved reliability, and lower costs in installation and operation, TE’s heavy duty connectors are suitable for numerous applications in servo and spindle motors. Designed to perform reliably under the most demanding conditions, TE’s heavy duty connectors offer IP69K rated protection and can endure 1,000 hours of salt spray resistance.These heavy duty connectors are built on a modular basis so they can offer power, signal and data transmission in a single compact unit. A one-piece connector frame allows for easy assembly of the modular inserts, and a docking frame that allows for blind mating provides more savings in installation time and costs. TE’s heavy duty connector has a history dating back over 60 years, during which time it has gone through various generations and options, offering special features for a wide range of applications. “The heavy duty connector is an iconic product that stands the test of time,” said Sascha Lambauer, Product Manager for TE’s heavy duty connectors. “Like many other TE solutions, the HDC also withstands harsh environments, reliably performing under demanding operating conditions, and is engineered to give designers flexibility and reliability in their servo and spindle motor designs.” Servo motors are increasingly being chosen for their high efficiency, especially in material handling systems and inside machinery. Meanwhile, advances in machine tooling requiring high precision and reliability are leading to spindle motors being put at the heart of modern production systems, delivering high quality end products.  Ref.KY270-106421-1KY270-1-1102296-1

Hirose has developed a hybrid power and signal board-to-board connector that features high-speed transmission capability up to 8 Gbps and a highly reliable floating contact mechanism that simplifies assembly. The FX23 Series is designed for a wide range of high-speed applications including medical devices, office imaging equipment, measurement equipment, industrial computer systems, automotive navigation and audio systems, broadcast equipment, base station transceivers, industrial machinery and more.A member of Hirose's FunctionMAX family of high-speed board-to-board connectors, the 0.5mm pitch FX23 Series connector supports high-speed applications with a specialized contact structure that utilizes a ground contact between adjacent differential pairs to reduce crosstalk. In addition, this contact structure provides superior impedance matching, even with short rise times.The connector's floating design offers a degree of play between the contacts during mating, allowing the board-to-board connector to absorb alignment errors up to ± 0.6mm in X and Y axis directions. By self-centering in both the X and Y directions, the floating structure eliminates mechanical stress at the SMT leads. This unique floating contact structure is particularly convenient when mating multiple connectors on the same printed circuit board, saving significant assembly time and costs.The hybrid power and signal connector has two built-in power contacts located on each side of the FX23 Series connector housing that provide a power rating of 3 Amps per pin. The hybrid structure also reduces the number of pins required, saving space. Available in right angle and parallel versions, the FX23 Series is offered in 20, 40, 60, 80, 100 and 120 positions. Source from Power Electronics