Connectors and interconnects are essential components enabling electrical and signal transmission between devices or systems. Defined as electromechanical interfaces, they ensure reliable connectivity while allowing for disconnection when needed. Their importance spans across industries, from consumer electronics to aerospace, where they support power delivery, data transfer, and system modularity. Modern technological advancements in 5G, IoT, and electric vehicles have driven innovations in high-speed, high-density, and high-reliability interconnect solutions.
| Type | Functional Characteristics | Application Examples |
|---|---|---|
| Board-to-Board Connectors | Direct PCB interconnection without cables | Smartphones, servers, industrial control systems |
| Wire-to-Wire Connectors | Joining cables or wires | Automotive wiring harnesses, home appliances |
| Wire-to-Board Connectors | Connect cables to PCBs | Medical devices, robotics |
| RF Connectors | High-frequency signal transmission | Telecom infrastructure, test equipment |
| Optical Fiber Connectors | Light signal transmission | Data centers, telecommunications |
Typical connectors consist of: - Contacts: Conductive elements (e.g., copper alloys) for electrical connection - Insulators: Thermoplastic or thermoset materials for contact separation - Housings: Protective shells (metal/plastic) with alignment features - Terminals: Connection points for wire/cable termination Advanced designs incorporate EMI shielding, anti-vibration mechanisms, and multi-layer contact plating (gold/tin over nickel).
| Parameter | Description | Importance |
|---|---|---|
| Current Rating | Maximum operational current (A) | Determines power handling capability |
| Contact Resistance | Resistance at mated contacts (m ) | Affects signal integrity and power loss |
| Dielectric Withstanding Voltage | Max voltage before breakdown (V) | Safety and insulation performance |
| Operating Temperature | Functional temperature range ( C) | Environmental reliability |
| Mating Cycles | Number of connect/disconnect cycles | Durability indicator |
| IP Rating | Ingress protection level | Dust/moisture resistance |
Major industries utilizing connectors include: - Consumer Electronics: USB Type-C, HDMI connectors - Automotive: EV charging connectors, CAN bus systems - Telecommunications: QSFP28 for 100Gbps data transfer - Industrial: Industrial Ethernet connectors (M12) - Medical: MRI machine interconnects with IP68 rating - Aerospace: MIL-DTL-38999 series connectors
| Manufacturer | Key Products |
|---|---|
| Amphenol Corporation | RFS-HP series RF connectors |
| TE Connectivity | MICROSET PLUG connectors |
| Molex LLC | PicoBlade wire-to-board connectors |
| Delphi Electronics | AXT150 automotive connectors |
| Samtec Inc. | Q Strip high-speed board-to-board |
Key considerations: 1. Define electrical requirements (current, voltage, frequency) 2. Assess environmental conditions (temperature, vibration, chemicals) 3. Determine mechanical needs (mating cycles, insertion force) 4. Ensure compliance with standards (IPC, MIL-STD, IEC) 5. Evaluate termination options (solder, crimp, press-fit) 6. Balance cost vs. reliability trade-offs
Emerging developments include: - Miniaturization: 0.4mm pitch connectors for mobile devices - High-speed transmission: 112Gbps differential pairs - High-voltage solutions: 1000V+ EV charging systems - Smart connectors with integrated sensors - Increased adoption of press-fit technologies - Transition to surface-mount designs for automated assembly - Growing demand for hermetically sealed connectors in harsh environments