With the continuous shrinking of electronic system volume and increasing density of functions, designers face the challenge of ensuring reliable interconnection. This is particularly prominent in the industrial, medical, military, and aerospace fields. In these fields, it is not only required that the connector structure be compact, but also capable of withstanding vibration, thermal cycling, and other stresses. To address these challenges, designers need compact interconnect solutions that combine reliability and space efficiency.
This article will explore the key requirements for such interconnections, including terminal density, reliable mating mechanisms, heat resistance, and signal and power levels. Then introduce Samtec's multifunctional connector ecosystem and explain how to use the system to meet these requirements.
Connector design and wire routing in compact layout
When selecting connectors for space constrained designs, contact distance (i.e. contact spacing) is the primary consideration. The smaller the spacing, the more compact the connector.
The diversity of connectors is equally important. For example, a single row connector may be the best choice for wires to pass through narrow spaces, while a double row connector can provide higher contact density. Similarly, the needle holder can be installed vertically or horizontally on a printed circuit board (PC board), making it easier to work in narrow gaps.
In addition, it is necessary to choose between ribbon cables and discrete wires. Although both solutions have their own advantages, the discrete wire solution can provide more routing options. This is particularly important in applications that require branch interconnection, as in such applications, a cable assembly must gather wires from multiple locations within the device (Figure 1).
Discrete wire system for simplifying wire aggregation
Figure 1: The figure shows a discrete wire system used to simplify wire aggregation and the use of multiple types of connectors in a single component. (Image source: Samtec)
Another advantage of discrete wires is that different styles of connectors can be used in one component to meet the requirements of different components and subsystems. Discrete wires can flexibly combine power and signal wires within components, and color codes can be used to identify the purpose of each wire.
The retention force and thermal compatibility of connectors under harsh conditions
Unintended disconnection during operation is one of the main factors threatening the reliability of interconnected devices. In larger systems, the use of fasteners such as screws, fasteners, or nuts can prevent interconnect components from separating under mechanical stress. However, smaller systems often lack space and therefore are not suitable for this method.
In systems that require frequent plugging, these challenges are even more complex. Frequent connections and disconnections require safe and easy-to-use maintenance methods, whether for maintenance needs, on-site upgrades, or reconfigurations.
To solve these problems, compact locking mechanisms are usually required. In this way, connectors can be securely plugged in and disconnected by hand without the need for tools or auxiliary fastening hardware.
Material selection is also an important consideration factor. The connector housing and wire insulation must be suitable for the specific environmental conditions of the application, including the expected operating temperature range and any applicable safety or regulatory requirements.
Power transmission and signal integrity in small interconnect devices
Although size is the main consideration in space constrained designs, small connectors still need to meet the corresponding electrical requirements. Even with small contact spacing, interconnect devices still need to ensure excellent signal quality and be able to carry sufficient current and voltage levels to support power supply requirements.
Given these factors, the design of contacts and terminals becomes increasingly important. Their geometric shape should ensure reliable contact spacing, and the materials used should be corrosion-resistant to maintain signal integrity over the long term. The dual elastic blade design is particularly useful in this situation, as it helps to maintain stable contact pressure over a wide temperature range and vibration conditions, which is crucial for avoiding signal loss or power interruption in harsh environments.
High performance interconnect platform suitable for space constrained systems
Samtec's Micro Mate discrete wire system is designed to meet the needs of space limited applications. The significant feature of the Micro Mate platform is its 1 mm contact spacing, which makes the packaging of the Quan series connectors very compact. The solution is suitable for cable to board, cable to cable, and cable to panel applications, greatly improving design flexibility. The main features of the Gecko SL series are as follows:
Single or double row configuration, with a total of 2 to 40 contacts, can meet various signal and input/output density requirements
Single latch or double latch mechanism ensures safe mating in mechanical pressure environments
Rated voltage up to 250 VAC and 353 VDC, with a rated current of up to 2.7 A per contact, capable of supporting both signal and moderate power transmission simultaneously
Double elastic blade gold-plated contact system ensures stable connection and excellent signal quality in harsh environments
Teflon fluoropolymer sheath can be selected to enhance chemical resistance and be compatible with halogen-free or high-temperature applications
In addition to standard cable components, Samtec also provides component level solutions for customized cabling. These solutions support the creation of customized component designs, maximizing space utilization and wiring flexibility for specific application designs.