Circular Connectors

Circular Connectors - Contacts

Image	Part Number	Description / PDF	Quantity	Rfq
	1603811 Phoenix Contact	CONTACT SOCKET 1.5MM CRIMP GOLD	0
	1605743 Phoenix Contact	CONTACT PIN 16-18AWG CRIMP GOLD	0
	1605736 Phoenix Contact	CONTACT PIN 16-18AWG CRIMP GOLD	0
	1603802 Phoenix Contact	CONTACT PIN SZ 1.5MM CRIMP GOLD	0
	1607920 Phoenix Contact	CONTACT SOCKET 1AWG CRIMP SILVER	0
	1414275 Phoenix Contact	CONTACT PIN 18-22AWG CRIMP GOLD	0
	1603498 Phoenix Contact	CONTACT PIN SZ 2.0MM CRIMP GOLD	0
	1623777 Phoenix Contact	CONTACT PIN 1.0MM CRIMP	0
	1603501 Phoenix Contact	RC-59S2000	0
	1623776 Phoenix Contact	CRIMP CONTACT, TURNED, CONTACT D	0
	1623775 Phoenix Contact	CONTACT SOCKET 1.5MM CRIMP	0
	1623380 Phoenix Contact	CRIMP CONTACT TURNED SINGLE CONT	0
	1623606 Phoenix Contact	CRIMP CONTACT TURNED CONTACT DIA	0
	1607579 Phoenix Contact	CONTACT PIN 20-22AWG CRIMP GOLD	0
	1607578 Phoenix Contact	CONTACT PIN 22-26AWG CRIMP GOLD	0
	1627290 Phoenix Contact	CRIMP CONTACT, TURNED, CONTACT D	0
	1607919 Phoenix Contact	CONTACT SOCKET 2AWG CRIMP SILVER	0
	1603800 Phoenix Contact	CONTACT SOCKET 1.0MM CRIMP GOLD	0
	1623383 Phoenix Contact	CRIMP CONTACT TURNED CONTACT DIA	0
	1623612 Phoenix Contact	CRIMP CONTACT TURNED SINGLE CONT	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).