1. Overview

Rectangular connectors - contacts are critical components in electrical systems, enabling reliable signal and power transmission between devices. Defined by their rectangular cross-section design, these connectors consist of male and female contact elements housed in insulating shells. Their importance spans modern electronics, automotive systems, industrial machinery, and communication infrastructure, where they ensure stable electrical connections while withstanding mechanical stress and environmental factors.

2. Main Types and Functional Classification

Type	Functional Characteristics	Application Examples
Power Contacts	High current capacity (up to 100A+), heavy-duty materials	Industrial power systems, EV charging interfaces
Signal Contacts	Low voltage/current, controlled impedance	Telecom equipment, PCB interconnects
Coaxial Contacts	360 shielding, controlled impedance (50/75 )	Radar systems, RF test equipment
High-Speed Data Contacts	Supports >10Gbps data rates, minimized crosstalk	Servers, data center switches
Hermetic Contacts	Sealed against environmental exposure	Aerospace sensors, underwater equipment

3. Structure and Components

Typical construction includes:

• Contact elements: Precision-machined copper alloys (C17200, C18150) with plating (Au, Ag, Sn)
• Insulation housing: High-temperature LCP or PBT thermoplastics
• Shell materials: Aluminum alloy or reinforced plastic with EMI shielding
• Termination types: Solder cup, PCB through-hole, or IDC (Insulation Displacement Connection)

Contacts feature spring-loaded designs for consistent normal force (typically 0.5-5.0N), with geometric optimizations to minimize insertion force and wear.

4. Key Technical Specifications

Parameter	Typical Range	Importance
Current Rating	1-100A	Determines power transmission capability
Contact Resistance	10m	Impacts signal integrity and power loss
Dielectric Withstanding Voltage	500-2500VAC	Ensures electrical safety
Mating Cycles	100-10,000 cycles	Defines mechanical lifespan
Temperature Range	-65 C to +200 C	Operating environment compatibility
Vibration Resistance	10-2000Hz, 10G	Reliability in dynamic environments

5. Application Fields

Primary industries include:

• Consumer Electronics: Smartphones, laptops, gaming consoles
• Automotive: ECU interfaces, sensor harnesses, ADAS systems
• Industrial Automation: PLCs, robotics, CNC machinery
• Medical Equipment: Diagnostic imaging systems, patient monitoring
• Aerospace: Avionics, flight control systems, satellite subsystems

Example: TE Connectivity's ARISO C Series connectors enable wireless charging systems in automated guided vehicles (AGVs).

6. Leading Manufacturers and Products

Manufacturer	Key Product Series	Notable Features
TE Connectivity	MATRIX	Modular design, up to 48 contacts
Amphenol	Mil-Circular	Military-grade hermetic sealing
Molex	PicoBlade	0.8mm pitch for compact devices
Delphi	WeatherPack	IP67-rated automotive connectors
ITT Cannon	VP Series	High-speed data transmission (25Gbps)

7. Selection Recommendations

Key considerations:

1. Current/voltage requirements with 20% safety margin
2. Environmental conditions (temperature, vibration, fluid exposure)
3. Space constraints (pitch size down to 0.4mm available)
4. Termination method compatibility (wave solder vs. reflow)
5. Compliance standards (IPC, MIL-STD, ISO 6722 for automotive)

For high-vibration environments like automotive applications, specify contacts with gold-plated beryllium copper springs.

8. Industry Trends

Emerging developments:

• Miniaturization: Sub-0.5mm pitch contacts for mobile devices
• High-speed evolution: 112Gbps differential pairs for 5G infrastructure
• Material innovation: Graphene-coated contacts for reduced friction
• Smart connectors: Integrated sensors for condition monitoring
• Eco-friendly plating: Elimination of hexavalent chromium in surface treatments

The market shows 6.8% CAGR through 2030, driven by electric vehicle and industrial IoT adoption according to Bishop & Associates research.