Chloe Zhang
Connectors are devices that join electrical terminations to create an electrical circuit. They are used to transmit power, data, and signals in diverse environments, from harsh industrial settings to intelligent buildings and electric vehicles. TE Connectivity and Molex are two manufacturers that offer a wide range of connector products. TE Connectivity's portfolio includes PCB connectors, wire connectors, and circular plastic connectors, while Molex specializes in USB connectors, board-to-board connectors, and memory card sockets. Both companies cater to various industries and applications, emphasizing reliability, performance, and versatility in their connector solutions.
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What You'll Learn
Circular plastic connectors
One example of a CPC is the MIL-C-5015 style circular plastic connector, which is an all-plastic connector designed to intermate with other manufacturers' metal-shell Mil-C-5015 type connectors. It is compatible with size 20-14 and 18-10 connectors and uses multimate size 16 contacts for reliable power and signal transmission. CPCs can be used in a wide range of applications, including automotive, marine, industrial automation, and control applications. They are engineered to reliably transmit data, power, and signal in diverse and extreme environments, making them a versatile and cost-effective solution.
TE Connectivity offers a broad range of connector components engineered for high-performance applications. Their AMPMODU interconnect products are suitable for various industries, and they also offer a comprehensive QSFP, QSFP+, and zQSFP+ interconnect portfolio. TE Connectivity also provides a broad set of USB connector technology solutions for I/O devices, including compact sockets and hot pluggability to ease installation. Their NECTOR power system is a flexible, fully pluggable, modular wiring, and sealed connector and cabling system for permanent power and data circuit electrical installations within intelligent buildings.
Molex is another manufacturer that offers a wide variety of connector solutions. They have been in the industry for 80+ years and provide reliable, high-quality solderless solutions, including terminals, splices, quick disconnects, and wire management products. Molex's specialty power connectors are designed for harsh environments, providing robust reliability and high performance. They also offer USB products, memory card sockets, and terminal blocks that can accommodate different wire sizes and types. Molex's industrial connectors are ruggedized and designed for harsh environmental conditions, providing improved reliability, enhanced flexibility, and improved performance for industrial networks and devices.
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Signal and power transmission
TE Connectivity's MIL-C-5015 style circular plastic connector is an all-plastic connector designed for signal and power transmission. It is compatible with size 20-14 and 18-10 connectors and uses multimate size 16 contacts. These connectors are designed for applications requiring signal, power, or both. Their circular configuration maximises space efficiency while offering enhanced design flexibility with various mounting options. They are built to perform in diverse environments, saving time, space, and money.
TE Connectivity also offers a range of other connectors for signal and power transmission. Their AMPACT wedge connectors are suitable for cables up to 3000 MCM in distribution, substation, and transmission applications up to 500 kV. Their AMPACT tap connectors use a metal wedge to secure the two conductors at opposing ends of the C-clamp, preventing creepage. TE Connectivity's interconnect systems are widely used in industrial applications requiring printed circuit boards (PCBs). Their AMPMODU interconnects provide a comprehensive family of modular signal interconnects for board-to-board, wire-to-board, and wire-to-wire applications, offering centreline flexibility.
Molex offers a wide range of connector solutions, including USB products, industrial connectors, and memory card sockets. Their USB products support high-data transmission rates and reliable connectivity. Molex Industrial Connectors provide ruggedised interconnect solutions designed for harsh environmental conditions, improving reliability, flexibility, and performance for industrial networks and devices. Their memory card sockets meet the quick and compact connection requirements of various industries.
Hirose Electric Group also provides electrical and electronic connectors, including high-speed signal transmission connectors, FPC/FFC one-piece connectors, and coaxial connectors. Their high-speed transmission connectors support board-to-board, board-to-cable, external I/O interface, and FPC/FFC connections. Hirose's ultra-small, low-profile products with high-speed transmission technology increase the design flexibility of wearables and mobile devices. Their coaxial connectors are available in standard and Hirose Original Microminiature options, with characteristic impedance of 50 or 75 ohms.
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Cost-effectiveness
Circular Plastic Connectors (CPC) are a cost-effective solution for a wide range of applications. They are lightweight, rugged, and reliable, making them suitable for harsh environments and diverse use cases. Their circular design maximises space efficiency, and they offer design flexibility with various mounting options. CPCs are easy to install and maintain, with features like quick connect/disconnect, thread assist, and positive dent coupling.
The cost-effectiveness of CPCs is particularly evident when compared to equivalent connectors with metal shells. While metal connectors are fully qualified to meet military specifications, they are also more expensive. In applications where extreme ruggedness is not required, such as certain military vehicles, plastic connectors provide a more affordable alternative. This is especially relevant in an era of reduced military spending.
Plastic connectors are also advantageous due to their lightweight nature, which can be crucial for applications that require minimal weight. This makes them a good choice for certain e-mobility solutions, where reducing weight is essential for efficiency. Additionally, in the agricultural sector, which is undergoing a technological revolution, plastic connectors can provide a cost-effective way to integrate electronic components into vehicles and equipment.
TE Connectivity's CPCs are constructed from heat-resistant, self-extinguishing thermoplastic, ensuring their durability and safety. They are available in six series, offering a range of mounting options for power, signal, and hybrid (power and signal) solutions. This versatility allows users to find a suitable CPC for their specific needs, optimising their investment.
While plastic connectors offer cost savings, it's important to consider the volume of production. At high volumes, plastic connector bodies can be produced inexpensively through injection moulding. However, at low volumes, custom plastic connectors become costly and are typically only available off-the-shelf. Nevertheless, 3D printing technology can provide a workaround, allowing custom mating connectors to be created from plastic filaments.
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Reliability in harsh environments
Plastic connectors are designed to work in a wide range of harsh environments, offering significant advantages over metal connectors. Their lightweight, durable, and cost-effective design makes them ideal for construction equipment, military vehicles, automated factories, and entertainment venues.
One of the key benefits of plastic connectors is their ability to withstand diverse environments. For example, the Amphenol ecomate® series is a lightweight, rugged circular connector with a high-impact thermoplastic design. These connectors are suitable for both indoor and outdoor applications in various industries, including factory automation, medical care, transportation, and heavy equipment. The ITT Cannon APD series is another popular option, featuring a high-quality thermoplastic housing that meets all environmental requirements for harsh applications such as agriculture, construction, heavy-duty trucks, and general industrial applications.
In addition to these widely used options, there are other plastic connectors specifically engineered for harsh industrial environments. For instance, the M12 X-coded connector provides solutions for Industrial IoT (IIOT) challenges, offering a compact and reliable connection system with environmental protection. This connector supports higher bandwidth needs, meeting the requirements of up to 10Gb/s.
To ensure the reliability of electrical connectors in harsh environments, protective measures are crucial. Connector covers, such as heat shrink tubing, provide excellent safety and stability by creating a tight protective seal around the connector. This type of cover is manufactured from thermoplastic and offers high resistance to moisture, chemicals, and UV light, making it ideal for outdoor or corrosive environments. Conduits and conduit fittings also play a vital role in safeguarding electrical connectors in harsh conditions. Conduits, typically made from metal, plastic, or fiber, act as robust shields, protecting wires from damage due to extreme temperatures, water, or physical impacts.
Overall, plastic connectors offer a reliable and cost-effective solution for a wide range of harsh environment applications. With their lightweight, rugged design and ability to withstand diverse conditions, they have become a popular choice across multiple industries. However, it is important to note that plastic connectors may not be suitable for all harsh environment applications, especially those requiring Mil-Spec connectors.
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Design flexibility
Circular Plastic Connectors (CPC) offer design flexibility in several ways. Firstly, they are lightweight and feature quick connect/disconnect, thread assist, and positive dent coupling for easy installation and maintenance. This makes them convenient for designers to work with and facilitates design changes. CPCs are also built with reliability and field repairs in mind, with replaceable parts such as the coupling ring. This means that they can be easily maintained and repaired without the need for complete replacement, allowing for flexibility in the long-term product design.
CPCs are made from heat-resistant, self-extinguishing thermoplastic, which offers enhanced design flexibility in terms of safety. Their circular configuration also maximizes space efficiency, allowing for more compact designs or additional components to be included. CPCs are compatible with various mounting options and are designed to perform in diverse environments, providing flexibility in the range of applications they can be used for.
The design of CPCs allows them to be used anywhere that signal and/or power are used to enter or exit a system. This versatility means they can be incorporated into a wide range of products and systems. CPCs are also compatible with size 20-14 and 18-10 connectors and use multimate size 16 contacts for reliable power and signal transmission, giving designers flexibility in the specific components they choose to work with.
In addition to CPCs, other connector products on the market also offer design flexibility. For example, Molex terminal blocks can accommodate different wire sizes and types, making them a popular choice across many industries. TE Connectivity's NECTOR power system is a flexible, fully pluggable, modular wiring, and cabling system for intelligent buildings. This system provides flexibility in the design of electrical installations within buildings.
Overall, circular plastic connectors, such as CPCs, offer design flexibility through their ease of use, safety features, space efficiency, compatibility, and versatility. These features enable designers to create more efficient, reliable, and adaptable products and systems.
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