Electrical Systems Codexery

Electrical connector

Electromechanical devices joining electrical circuits via conductors.

Last updated

An electrical connector is an electromechanical device that creates an electrical connection between parts of a circuit, joining them into a larger circuit.[1] Connections between two points can be permanent, require a tool for assembly and removal, or be removable, as is the case for portable equipment.[2] Manufacturers produce numerous connector configurations for audiovisual, data, and power applications.[3]

Quick Facts

Field
Electrical engineering, electronics
Categories
  • Inline
  • chassis
  • PCB mount
  • splice/butt connectors
Common materials
  • Copper alloys (conductors)
  • plastics (insulators)
  • gold coatings
Failure modes
  • Intermittent connections
  • open contacts
  • fretting
  • surface corrosion

Facts from the source article.

Key facts and history

Electrodes in connectors are usually made of copper alloys due to their good conductivity and malleability.[4] Many connectors used in electronics are plated with gold to allow low-voltage, low-resistance signal transmission because gold has no surface oxide layer.[5] The majority of connector failures result in intermittent connections or open contacts.[6] Connectors are purely passive components and should affect circuit function as little as possible.[7]

Crimped connectors are a type of solderless connection using mechanical friction and uniform deformation to secure a connector to a wire.[1] Plastic is the typical material for contact carriers because it provides insulation.[4] Circular connectors find frequent use where rugged mechanical performance, tight environmental sealing, and easier engagement are needed.[8] A mechanical component, sometimes called a keyway, is used to key many connectors so they cannot be mated in the wrong orientation.[9]

To prevent poor environmental sealing or accidental disconnection, some connector housings incorporate locking mechanisms.[1]

What the cited sources add

The Lascelles article notes that QA Technology’s IDO2 Series circular connectors are ubiquitous in medical electronics, instrumentation, and military and aerospace equipment.[10] Modern hyperboloid contacts have reduced engagement forces, about 40% lower than conventional contacts.[10] A 78-position circular connector with 2A-rated signal contacts using new hyperboloid contacts needs only 2.45 Kgf to be mated.[10] The Brearley article states that Francois Bonhomme invented a new connector in the mid-1950s to address the needs of the rail industry.[11]

Designs using Smiths Connectors hyperboloid contacts are typically rated for 30-40% more current than comparable screw machine or stamped contact designs.[11] The Jet Propulsion Laboratory of NASA has done extensive testing validating that connectors with hyperboloid contacts are well suited to the rigors of outer space.[11] European trains continue to use connectors with hyperboloid contacts over 50 years after they were invented.[11]

References

  1. Wikipedia, "Electrical connector" (CC BY-SA 4.0), which cites: "Electrical Connectors Information", Engineering360 (original not read by us) en.wikipedia.org
  2. Wikipedia, "Electrical connector" (CC BY-SA 4.0), which cites: Mroczkowski, "Electrical Connector Handbook: Theory and Applications", McGraw Hill, 1998 (original not read by us) en.wikipedia.org
  3. Wikipedia, "Electrical connector" (CC BY-SA 4.0), which cites: Elliott, "Electromechanical Devices & Components", McGraw-Hill Professional, 2007; "Connector Basics", SparkFun; David, "Engineering Definitions – 'Com' to 'Con'", Electronic Engineering Dictionary Terms, 17 March 2012; Horowitz, "The Art of Electronics", Cambridge University Press, 1989 (we also read that source) en.wikipedia.org
  4. Wikipedia, "Electrical connector" (CC BY-SA 4.0), which cites: "Connectors – Technologies and Trends", ZVEI – German Electrical and Electronic Manufacturers’ Association, August 2016 (original not read by us) en.wikipedia.org
  5. Wikipedia, "Electrical connector" (CC BY-SA 4.0), which cites: https://ieeexplore.ieee.org/document/6336595; https://ieeexplore.ieee.org/document/9295164; https://www.google.com.pa/books/edition/Electrical_Connectors/VL8OEAAAQBAJ?hl=en&gbpv=1&dq=gold+in+electronic+connectors&pg=PA44&printsec=frontcover; https://ieeexplore.ieee.org/document/1135985; https://ieeexplore.ieee.org/document/6228871; https://www.connectortips.com/gold-alternatives-connector-designs/; https://ieeexplore.ieee.org/document/113030; https://ieeexplore.ieee.org/document/1136211 (original not read by us) en.wikipedia.org
  6. Wikipedia, "Electrical connector" (CC BY-SA 4.0), which cites: "Connectors: Failure Mechanisms and Anomalies", Naval Sea Systems Command; Normalized failure mode distributions were originally compiled from a combination of: MIL-HDBK-978, “NASA Parts Application Handbook”, 1991; MIL-HDBK-338, “Elec (original not read by us) en.wikipedia.org
  7. Wikipedia, "Electrical connector" (CC BY-SA 4.0), which cites: "Connectors: Failure Mechanisms and Anomalies", Naval Sea Systems Command (original not read by us) en.wikipedia.org
  8. Wikipedia, "Electrical connector" (CC BY-SA 4.0), which cites: "Essential Connector Terms and Definitions for Specifiers of Interconnect Wiring Systems", Glenair, Inc, 2004 (original not read by us) en.wikipedia.org
  9. Wikipedia, "Electrical connector" (CC BY-SA 4.0), which cites: Worley, "Circular Connector Terminology Guide", NYK Component Solutions, 31 July 2018; "Electrical Connectors Information", Engineering360 (original not read by us) en.wikipedia.org
  10. Lascelles, "Modern Hyperboloid Contacts for Circular I/O Connectors", ConnectorSupplier.com, 8 June 2015. facts only, no text reused. connectorsupplier.com
  11. David Brearley, "Would you trust your life to a 50-year old connector design?", Connector Tips, 9 October 2015. facts only, no text reused. connectortips.com

Each numbered sentence above was checked against the source it cites before publication. Sentences citing Wikipedia adapt text from the English Wikipedia article Electrical connector (contributors), used under CC BY-SA 4.0; this entry is available under the same licence. Other sources were used for facts only; no text or images are copied from them.

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Sources

Compiled from Wikipedia and the sources listed below. Text from Wikipedia is available under CC BY-SA 4.0; this entry is adapted from it.

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