Rectangular Connectors - Spring Loaded

Part Number	Description / PDF	Quantity
858-22-003-80-012101 Mill-Max	CONN SPRING PISTON 3POS PCB	109
818-22-072-10-006101 Mill-Max	CONN SPRING PISTON 72POS PCB	0
821-22-027-10-004101 Mill-Max	CONN SPRING PISTON 27POS PCB	0
821-22-005-10-003101 Mill-Max	CONN SPRING PISTON 5POS PCB	0
319-10-104-00-006000 Mill-Max	CONN SPRING TARGET 4POS PCB	681
826-22-008-00-005000 Mill-Max	CONN SPRING PISTON 8POS SLD PCB	67
821-22-012-10-001101 Mill-Max	CONN SPRING PISTON 12POS PCB	0
818-22-008-10-004101 Mill-Max	CONN SPRING PISTON 8POS PCB	198
816-22-002-10-004101 Mill-Max	CONN SPRING PISTON 2POS PCB	947
823-22-016-10-000101 Mill-Max	CONN SPRING PISTON 16POS PCB	0
815-22-015-30-001101 Mill-Max	CONN SPRING PISTON 15POS SMD	0
811-22-064-30-004101 Mill-Max	CONN SPRING PISTON 64POS SMD	7
813-22-044-30-001101 Mill-Max	CONN SPRING PISTON 44POS SMD	0
823-22-004-10-004101 Mill-Max	CONN SPRING PISTON 4POS PCB	0
827-22-006-10-004101 Mill-Max	CONN SPRING PISTON 6POS PCB	217
821-22-025-10-002101 Mill-Max	CONN SPRING PISTON 25POS PCB	0
499-10-264-10-008000 Mill-Max	CONN SPRING TARGET 64POS R/A PCB	36
814-22-008-30-030101 Mill-Max	FMLB SPRING-LOADED CONN, SMT DOU	147
812-22-038-30-000101 Mill-Max	CONN SPRING PISTON 38POS SMD	0
868-22-003-00-011101 Mill-Max	CONN SPRING PISTON 3POS SLD PCB	69

Rectangular Connectors - Spring Loaded

1. Overview

Spring loaded rectangular connectors are a specialized type of electrical interconnect system featuring spring-actuated contact elements. Their design enables reliable electrical connections in applications requiring high mating cycles, vibration resistance, and precise alignment compensation. These connectors play a critical role in modern electronics by enabling robust power and signal transmission in challenging environments such as automotive testing, industrial automation, and medical equipment.

2. Main Types and Functional Classification

Type	Functional Characteristics	Application Examples
Board-to-Board	Self-aligning contacts for PCB stacking	Telecom backplanes, server racks
Wire-to-Board	Daisy-chain wiring solutions	Industrial sensors, test equipment
High-Density	Miniaturized contact arrays	Medical imaging devices, UAVs
High-Current	Multi-point contact design for >50A	EVTOL charging systems, battery packs
Hermetic	Sealed against environmental factors	Aerospace avionics, underwater sensors

3. Structure and Components

Typical construction includes:

Contact Elements: Phosphor bronze or beryllium copper with gold plating
Insulation Housing: High-temperature thermoplastics (LCP, PPS)
Actuation Mechanism: Precision compression springs (0.5-5N force range)
Shielding: Optional EMI/RFI protection layers
Retention System: Mechanical latches or magnetic assist

4. Key Technical Specifications

Parameter	Typical Range	Importance
Current Rating	1-200A/contact	Determines power capacity
Contact Resistance	5-20m	Affects signal integrity
Dielectric Strength	500-2500VAC	Safety isolation
Mating Cycles	10k-100k	Service lifetime
Operating Temp	-55 C to +150 C	Environmental tolerance
Vibration Resistance	20G-50G	Reliability in motion

5. Application Fields

Primary industries:

Telecommunications: 5G base stations, optical transceivers
Industrial Automation: Robotic arms, conveyor systems
Military/Aviation: Radar systems, flight control panels
Medical: Patient monitoring systems, MRI equipment
Automotive: EV battery test fixtures, autonomous driving sensors

6. Leading Manufacturers and Products

Manufacturer	Product Series	Key Features
Amphenol	BLADE Series	Modular design, 100G vibration resistance
Molex	Pogo Pin System	Self-cleaning contacts, 100k cycles
TE Connectivity	MICROCHOICE	0.8mm pitch, 10GB/s data rate
Samtec	SEARAY	High-density array, IP68 rating
ITT Cannon	VI-LINK	Optical-electrical hybrid integration

7. Selection Guidelines

Key considerations:

Determine current/voltage requirements with safety margins
Evaluate environmental conditions (temperature, humidity, shock)
Match contact pitch with PCB layout constraints
Consider termination type (solder, crimp, press-fit)
Verify compliance with standards (IPC, MIL-STD)
Calculate total cost of ownership including maintenance

8. Industry Trends

Emerging developments:

Miniaturization: 0.4mm pitch connectors for wearable devices
High-speed capabilities: 56Gbps differential pairs
Smart integration: Embedded sensors for condition monitoring
Eco-friendly materials: Halogen-free polymers and lead-free plating
Automated mating: Robotics-compatible alignment systems