Increasingly, “rugged” connectors, which are resistant to harsh conditions, are in demand. This term, however, borrowed from industries such as aerospace or transportation, does not apply uniquely to connectors because it can refer to a variety of aspects of connector design.
Vibration
The first factors to consider when talking about use in extreme environments are vibration, which can make an unstable and unreliable connection between two connectors or between the connector and the PCB.
A stable, reliable, and secure contact between an SMT connector and the PCB can be achieved with optimized contact design for soldering purposes.
For example, the contacts of Ept's One27 Connector (SMT Connector) are designed to ensure excellent connection to the pcb during soldering, evidenced by the meniscus formed on the solder. In addition, the One27 connector also has a metal reinforcement, which is also soldered to the pcb so that the connector is anchored to the pcb in an extremely stable manner.
When mating, the connectors can be improved by design at the design stage to increase the stability of the contact even in the presence of vibration. This explains why Ept's female contact is designed double-sided and flexible to ensure that at least one part of the contact is always adhered to the male contact and there are no transmission interruptions. The One27 connector has been tested in a 10-2000Hz frequency range according to IEC 60068-2-6:2007 standards, as well as under 50 G shock according to IEC 60068-2-27:2008.
A stable, reliable, and secure contact between an SMT connector and the PCB can be achieved with optimized contact design for soldering purposes.
For example, the contacts of Ept's One27 Connector (SMT Connector) are designed to ensure excellent connection to the pcb during soldering, evidenced by the meniscus formed on the solder. In addition, the One27 connector also has a metal reinforcement, which is also soldered to the pcb so that the connector is anchored to the pcb in an extremely stable manner.
When mating, the connectors can be improved by design at the design stage to increase the stability of the contact even in the presence of vibration. This explains why Ept's female contact is designed double-sided and flexible to ensure that at least one part of the contact is always adhered to the male contact and there are no transmission interruptions. The One27 connector has been tested in a 10-2000Hz frequency range according to IEC 60068-2-6:2007 standards, as well as under 50 G shock according to IEC 60068-2-27:2008.
Durability
A second relevant factor is the durability of a connector understood as the number of mating possible without affecting the quality of signal transmission. The most important aspect is the quality of plating. A quality, durable and smooth plating reduces friction during mating. In addition, greater thickness allows more mating before losing functionality.
Particularly in Ept's One27 connector, this has been achieved with a sophisticated design of the female contact and the rounded, very smooth shape of the male contact, which allow for minimal non-homogeneity and angular surfaces that would increase friction.
Due to its design, the One27 connector is rated “Performace Level 1” which results in 500 mating cycles, even in harsh environments such as exposure to corrosive gases (IEC 60068-2-60:2015) or frequent temperature fluctuations (IEC 60068-2-30:2005), without losing any properties over time.
In addition, the extended and rounded contact surface of the female contact allows higher electrical conductivity due to low contact resistance.
Particularly in Ept's One27 connector, this has been achieved with a sophisticated design of the female contact and the rounded, very smooth shape of the male contact, which allow for minimal non-homogeneity and angular surfaces that would increase friction.
Due to its design, the One27 connector is rated “Performace Level 1” which results in 500 mating cycles, even in harsh environments such as exposure to corrosive gases (IEC 60068-2-60:2015) or frequent temperature fluctuations (IEC 60068-2-30:2005), without losing any properties over time.
In addition, the extended and rounded contact surface of the female contact allows higher electrical conductivity due to low contact resistance.
Processing & Handling
Ultimately, connectors also need to be robust during assembly.
The “board lock” described above also fulfills the function of absorbing mechanical forces during assembly. SMT connectors have been positively tested with forces up to 400 N.
During the mating process, high tolerance compensation facilitates assembly. In particular, assembly of Ept's One27 connector is facilitated by the combination of the sophisticated design of the two-sided female contact and the flexibility of the male contact, as well as by the conformation of the insulation material, which allows slanted insertion with a tolerance of 0.7mm in either direction, and a longitudinal angle of ±4° (and transverse angle of ±2°).
The “board lock” described above also fulfills the function of absorbing mechanical forces during assembly. SMT connectors have been positively tested with forces up to 400 N.
During the mating process, high tolerance compensation facilitates assembly. In particular, assembly of Ept's One27 connector is facilitated by the combination of the sophisticated design of the two-sided female contact and the flexibility of the male contact, as well as by the conformation of the insulation material, which allows slanted insertion with a tolerance of 0.7mm in either direction, and a longitudinal angle of ±4° (and transverse angle of ±2°).
The shape of the female contact ensures, even after assembly, that the contact remains with a male-to-female distance of up to 1.5mm. This aspect makes the One27 connector versatile when board-to-board distances are defined, as well as ensuring tolerance on distances by connecting two pcbs.
In conclusion, the aspects that make a connector robust in all respects are many, with more or less relevant aspects depending on the application.
For example, should the connector be able to absorb mechanical forces during assembly? Or only during operation? Will it be exposed to corrosive environments? Or must they be mated frequently?
The answer to these and many other questions is crucial in determining which aspects are most relevant in choosing the most suitable connector for that specific application.
Orvem with its engineers is the ideal partner to support you in choosing the best and most suitable connector for your applications, together with Ept connectors.
In conclusion, the aspects that make a connector robust in all respects are many, with more or less relevant aspects depending on the application.
For example, should the connector be able to absorb mechanical forces during assembly? Or only during operation? Will it be exposed to corrosive environments? Or must they be mated frequently?
The answer to these and many other questions is crucial in determining which aspects are most relevant in choosing the most suitable connector for that specific application.
Orvem with its engineers is the ideal partner to support you in choosing the best and most suitable connector for your applications, together with Ept connectors.
