Heavy Duty Connectors

Heavy Duty Connectors - Contacts

Part Number	Description / PDF	Quantity
11190300 LAPP	CONN CNT SLV PIN 2.5MM 14AWG	543
13163800 LAPP	CONN CNT GLD SKT 1.6MM 16AWG	134
11195200 LAPP	CONN CNT SLV SKT 2.5MM 16AWG	680
13163600 LAPP	CONN CNT GLD SKT 1.6MM 20AWG	908
44423246 LAPP	CONN CNT SLV SKT 8MM 8AWG	30
44423258 LAPP	CONN CNT SLV SKT 4MM 10AWG	300
11195400 LAPP	CONN CNT SLV SKT 2.5MM 12AWG	940
13163700 LAPP	CONN CNT GLD SKT 1.6MM 18AWG	90
13162200 LAPP	CONN CNT SLV PIN 1.6MM 18AWG	600
11236100 LAPP	CONN CNT SLV SKT 1.5MM 20-16AWG	400
13162800 LAPP	CONN CNT GLD PIN 1.6MM 16AWG	280
11195100 LAPP	CONN CNT SLV SKT 2.5MM 18AWG	860
13162100 LAPP	CONN CNT SLV PIN 1.6MM 20AWG	1220
13162400 LAPP	CONN CNT SLV PIN 1.6MM 14AWG	500
13162700 LAPP	CONN CNT GLD PIN 1.6MM 18AWG	0
44423253 LAPP	CONN CNT SLV PIN 4MM 10AWG	300
11192200 LAPP	CONN CNT GLD PIN 2.5MM 16AWG	150
11197100 LAPP	CONN CNT GLD SKT 2.5MM 18AWG	100
13163500 LAPP	CONN CNT GLD SKT 1.6MM 26-22AWG	300
44423257 LAPP	CONN CNT SLV SKT 4MM 12AWG	290

Heavy Duty Connectors - Contacts

1. Overview

Heavy duty connectors - contacts are specialized electrical components designed to establish reliable conductive pathways in high-current, high-voltage, or harsh-environment applications. These contacts serve as critical interface points in power transmission systems, industrial machinery, and transportation infrastructure. Their importance continues to grow with advancements in electrification, renewable energy systems, and automated manufacturing processes.

2. Main Types and Functional Classification

Type	Functional Characteristics	Application Examples
Bolted Contacts	High mechanical stability, screw-terminal connections	Power distribution panels, heavy machinery
Blade Contacts	Quick-insert design with positive lock mechanism	Automotive systems, battery packs
Circular Contacts	360 rotational connectivity	Rotary unions, wind turbines
Printed Circuit Contacts	Surface-mount compatible with PCB integration	Industrial control systems, automation equipment

3. Structure and Components

Typical construction includes:

Contact body: Copper alloys (C18150, C11000) or aluminum alloys
Contact surface: Silver-plated or tin-coated for enhanced conductivity
Insulation housing: Thermoplastic (PBT) or thermoset materials
Locking mechanism: Bayonet, threaded, or spring-loaded systems
Environmental seals: IP65-rated gaskets and O-rings

Modular designs often incorporate replaceable contact inserts and integrated cooling channels.

4. Key Technical Specifications

Parameter	Typical Range	Importance
Current Rating	100A - 5000A	Determines power transmission capacity
Voltage Rating	600V - 15kV	Ensures dielectric safety
Contact Resistance	<0.1m - 0.5m	Impacts thermal performance
Temperature Range	-55 C to +150 C	Defines operational envelope
Insertion Force	50N - 200N	Affects mating durability

5. Application Fields

Energy: Power generation equipment, grid infrastructure
Transportation: Electric vehicles, rail systems, marine propulsion
Industrial: CNC machinery, welding robots, factory automation
Renewables: Wind turbine converters, solar inverters
Military/Aerospace: Avionics systems, defense equipment

6. Leading Manufacturers and Products

Manufacturer	Representative Product	Key Features
TE Connectivity	XD Connector System	1500A rating, quick-make design
Amphenol Industrial	MAXRAD High Power	IP67 protection, 3-phase configuration
Delphi Automotive	EVP High Voltage Connector	800V capability, fault current protection

7. Selection Recommendations

Key considerations:

Current/voltage requirements with 20% safety margin
Environmental protection (IP rating, corrosion resistance)
Mating cycle requirements (1000-10,000+ cycles)
Compliance with standards (IEC 60999, UL 486A-B)
Thermal derating for ambient temperatures >40 C

Case study: For wind turbine generator connections, specify silver-plated contacts with IP65 sealing and vibration damping features.

8. Industry Trends

Current developments include:

Miniaturization while maintaining high current density
Integration with smart monitoring (IoT-enabled contacts)
Advanced coating technologies (graphene-enhanced surfaces)
Increased focus on recyclable materials
Hybrid designs combining power and signal transmission