Circular Connectors

Circular Connectors - Contacts

Part Number	Description / PDF	Quantity
HR22-SC-122 Hirose	CONTACT SOCKET 24-28AWG CRIMP	3666
ZN01 015 0047 1 Tuchel / Amphenol	CONTACT PIN 18AWG CRIMP SILVER	0
66728-5 TE Connectivity AMP Connectors	CONTACT PIN 22-28AWG CRIMP TIN	4467
CIRB12KSKF80 TE Connectivity AMP Connectors	SIZE 12 SOCKET CONTACT	57
82911467NK Souriau-Sunbank by Eaton	CONTACT PIN 12AWG CRIMP GOLD	18
031-8646-003 VEAM	CONTACT SOCKET 6AWG CRIMP SILVER	74
M39029/56-351 TE Connectivity DEUTSCH Connectors	CONTACT SOCKET 20-24AWG CRIMP	18105
M39029/83-450 TE Connectivity DEUTSCH Connectors	CONTACT PIN 22-26AWG CRIMP GOLD	0
09151006101 HARTING	HAN M23 MALE CRIMP CONTACT, 1MM,	294
TN0101600111 Tuchel / Amphenol	CONTACT PIN 20-26AWG CRIMP SLVR	0
APK-SA16A15-002 VEAM	CONTACT SOCKET CRIMP TIN	14830
SS20M2F Tuchel / Amphenol	CONTACT SOCKET 20-22AWG SZ16	5391
SC000463 Tuchel / Amphenol	CONTACT PIN 14-18AWG 2.0MM CRIMP	148
SC20WL-3S25 Souriau-Sunbank by Eaton	CONTACT SOCKET 20-22AWG CRIMP	3422
SC000039 Tuchel / Amphenol	CONTACT SOCKET 8-12AWG CRIMP	138900
1605559 Phoenix Contact	CONTACT PIN SZ 1.0MM CRIMP GOLD	100
APK-SB25A10-002 VEAM	CONTACT SOCKET SZ2.5MM CRIMP TIN	4400
M39029/28-409 TE Connectivity DEUTSCH Connectors	CONTACT PIN SZ 12 CRIMP GOLD	133
FGG.2B.555.ZZC REDEL / LEMO	CONTACT PIN 22-26AWG CRIMP GOLD	337
SP24M1F Tuchel / Amphenol	CONTACT PIN 24-26AWG CRIMP GOLD	0

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).