Mouser - White Papers

Mouser Electronics White Paper Too little retaining force can result in an unreliable connection, especially when subjected to vibration. However, if too much force is generated, the mating process can damage the plating and impair performance. Therefore, designing the mating interface is a balance between maintaining mechanical stability and minimizing wear. Material selection requires a careful balance of physical strength, conductivity, and corrosion resistance. Most contacts are manufactured from copper alloys, which provide excellent conductivity (Figure 3). In other applications, beryllium copper is often preferred due to its greater spring force. However, these materials alone do not deliver all the required characteristics. Contacts are usually plated to guard against corrosion. Gold is the common plating option because it conducts well and does not oxidize. Its softness also reduces friction during mating, helping the connector last longer. Military specifications clearly define the materials and plating required to ensure consistent performance. Connectors provide true reliability only when their contacts are engineered to meet these standards. With the right material choices and the right care, connectors can continue to perform as expected, even after thousands of mating cycles. The Whole Connector Although contacts define electrical performance, the rest of the connector can't be overlooked. From the housing that shields against impact to the latch that resists vibration, each feature is engineered to keep the system working in harsh environments. Figure 3: Connector contacts use layered materials, often including copper alloy, to balance strength, elasticity, and long-term signal integrity. (Source: Molex) Housings The outer housing of a connector provides mechanical strength and environmental protection for the components inside. As with contacts, material choice plays a significant role in connector performance, and engineers will typically choose between polymer and metal housings. • Polymer housings: The high- performance polymers used in rugged connectors are strong and light. Weight savings are critical in aerospace, ground, and naval applications. Polymers resist corrosion, but long-term exposure to sunlight can weaken some materials. • Metal housings: Metal connector housings are conductive, delivering excellent shielding against electromagnetic interference (EMI). While they are also strong, they may require surface treatment to protect them against environmental effects, especially those of salt water. Connectors designed for use in satellite and space applications face specific challenges. The vacuum of space exposes components directly to harsh radiation, so the materials used for connector housings must include radiation stability. Space- rated connectors use polymers and metals certified to standards such as NASA ASTM-E595 and EEE-INST-002, ensuring reliability in extreme space environments.

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