Circular Connectors

Circular Connectors - Contacts

Part Number	Description / PDF	Quantity
CC81L-2830-01-L Samtec, Inc.	CONTACT SOCKET 28-30AWG CRIMP	6031
929990-1 TE Connectivity AMP Connectors	CONTACT SOCKET 13-17AWG CRIMP	7111
09151006201 HARTING	HAN M23 FEMALE CRIMP CONTACT, 1M	196
APK-PB25A40-002 VEAM	CONTACT PIN SZ 2.5MM CRIMP TIN	6752
SP20W2G30 Tuchel / Amphenol	CONTACT PIN 20-22AWG SZ20 CRIMP	0
SA3347 Bulgin	CONTACT SOCKET 22-26AWG 1=10PC	0
ST-JL05-20S-C1-100 JAE Electronics	CONTACT SOCKET 18-22AWG CRIMP	0
105976 TE Connectivity DEUTSCH Connectors	CONT SOC ASSY	0
031-8646-015 VEAM	CONTACT SOCKET SZ 0 CRIMP SILVER	0
CM16PC00MQ Souriau-Sunbank by Eaton	CONTACT PIN 13-18AWG CRIMP GOLD	0
1170180000 Weidmuller	CONTACT SOCKET 1.0MM CRIMP GOLD	160
M39029/90-529 TE Connectivity DEUTSCH Connectors	CONTACT PIN SZ 8 CRIMP GOLD	569
EGG.1B.665.ZZM REDEL / LEMO	CONTACT SOCKET 18-20AWG CRIMP	0
SA3180 Bulgin	CONTACT PIN 24-28AWG 1=10PC	22
M39029/5-115 Preci-Dip	CONTACT SIZE 20 SOCKET, 20 AWG	12843
APKPB25H25002 VEAM	CONTACT PIN SZ 2.5MM CRIMP GOLD	0
SC000385 Tuchel / Amphenol	CONTACT SOCKET 24-28AWG CRIMP	477
SS24M2G5 Tuchel / Amphenol	CONTACT SOCKET 24AWG SZ16 CRIMP	0
HR10B-2.5CP(73) Hirose	CONTACT SOCKET COAX CRIMP SLDR	0
SA3623/S Bulgin	CONTACT SOCKET 18-20AWG 1=10PC	2

Circular Connectors - Contacts

1. Overview

Circular connectors - contacts are electro-mechanical components designed to establish electrical connections between circuits in a circular interface configuration. These contacts serve as critical conduits for power, signal, or data transmission in complex systems. Their importance spans across industries requiring reliable connectivity in harsh environments, including aerospace, industrial automation, and medical devices. Modern advancements demand miniaturization, higher bandwidth, and improved durability in these components.

2. Main Types & Functional Classification

Type	Functional Characteristics	Application Examples
Power Contacts	High current capacity (up to 100A), thermal resistance	Industrial machinery, EV charging stations
Signal Contacts	Low noise, impedance control	Telecom equipment, control systems
Coaxial Contacts	50/75 impedance, EMI shielding	Radar systems, test equipment
Fiber Optic Contacts	Low insertion loss, multi-channel transmission	High-speed data networks, avionics
Hybrid Contacts	Combined power/signal/data in single interface	Autonomous vehicle sensors, robotics

3. Structure & Composition

Typical construction includes:

Contact pins/sockets: Copper alloys (phosphor bronze, beryllium copper) with plating (gold, silver, tin)
Insulation housing: Thermoplastic (LCP, PBT) or thermoset materials
Shell: Aluminum, stainless steel, or composite materials
Contact retention system: Spring-loaded mechanisms for vibration resistance
Environmental seals: Elastomer gaskets for IP67+ protection

Modular designs allow mixed contact configurations with polarization keys to prevent mis-mating.

4. Key Technical Specifications

Parameter	Typical Range	Importance
Current Rating	1-100A	Determines power transmission capability
Voltage Rating	50-1500V	Safety and insulation performance
Contact Resistance	1-15m	Signal integrity and power efficiency
Insulation Resistance	100M -10G	EI/EMC compliance
Temperature Range	-65 C to +200 C	Environmental durability
Mating Cycles	500-10,000	Service life and reliability

5. Application Fields

Aerospace: Flight control systems, in-flight entertainment
Industrial Automation: Robotics, CNC machines
Medical Equipment: MRI scanners, patient monitoring systems
Transportation: Rail signaling, automotive sensors
Defense: Radar systems, secure communications

Case Study: In wind turbines, circular connectors handle pitch control signals with IP68 protection against dust/moisture.

6. Leading Manufacturers

Manufacturer	Representative Product	Key Features
Amphenol	Series 800 Circular	High-speed data transmission up to 10Gbps
TE Connectivity	DEUTSCH DT Series	Extreme temperature resistance (-65 C to +200 C)
Molex	Circular MIL-DTL-38999	Shock/vibration rated for military vehicles
Delphi	Mini-Circular Connector	Compact design for automotive sensor networks

7. Selection Guidelines

Key considerations:

Current/voltage requirements vs. contact material properties
Environmental protection level (IP rating)
Mating/unmating force requirements
Signal integrity needs (frequency, crosstalk)
Compliance with standards (MIL-DTL-38999, IEC 61076)
Cost vs. lifecycle trade-offs

Recommendation: Aerospace applications should prioritize weight reduction with composite shells, while industrial uses need corrosion-resistant plating.

8. Industry Trends

Emerging developments include:

Micro-miniaturization for IoT device integration
High-speed contacts supporting 40+ Gbps data rates
Smart connectors with integrated sensors
Alternative plating materials (nanocoatings) for RoHS compliance
Modular hybrid designs combining power/optical contacts

Market growth driven by 5G infrastructure and electric vehicle adoption, projected CAGR of 6.8% (2023-2030).