Circular Connectors

Circular Connectors - Contacts

Part Number	Description / PDF	Quantity
1-2314103-1 TE Connectivity AMP Connectors	CONTACT SOCKET 20AWG 1MM CRIMP	301
M39029/16-168 TE Connectivity DEUTSCH Connectors	CONTACT SOCKET 20-24AWG CRIMP	2456
SP28W2G10 Tuchel / Amphenol	CONTACT PIN 28-30AWG SZ20 CRIMP	0
CONT-JL05-12P-C1-10 JAE Electronics	CONTACT PIN 12-16AWG CRIMP SLVR	0
SC000146 Tuchel / Amphenol	CONTACT PIN 24-28AWG CRIMP GOLD	131000
SC000263 Tuchel / Amphenol	CONTACT PIN 22-28AWG	632
SC000264 Tuchel / Amphenol	CONTACT SOCKET 22-28AWG	351
MP-108600 Tuchel / Amphenol	MP SERIES COMBO CRIMP/SOLDER #16	0
1618458 Phoenix Contact	CONTACT PIN ST-10KP035	964
82911459NK Souriau-Sunbank by Eaton	CONTACT PIN 20AWG CRIMP GOLD	0
1452356 Phoenix Contact	CONTACT PIN SZ 1.0MM CRIMP GOLD	18
SS24W2G15 Tuchel / Amphenol	CONTACT SOCKET 24AWG SZ20 CRIMP	0
VN0201500471 Tuchel / Amphenol	CONTACT SOCKET 18AWG CRIMP SLVR	75
HR30-PC-211 Hirose	CONTACT PIN 26-30AWG CRIMP GOLD	0
929967-1 TE Connectivity AMP Connectors	CONTACT PIN 17-20AWG CRIMP TIN	0
HR41-SC-111 Hirose	CONTACT SOCKET 10-12AWG CRIMP	2
27P-KITCON-24S12-3S10 TE Connectivity AMP Connectors	CONTACT KIT FOR PLUG	6
TN01 025 0001 2 Tuchel / Amphenol	CONTACT PIN 16-20AWG CRIMP GOLD	0
AT62-203-04141 Tuchel / Amphenol	CONTACT SOCKET 6AWG SZ4 CRIMP	48
97-45-1622S-4(0920) Amphenol Industrial	CONTACT SOCKET 16-22AWG 1=100	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).