The basic performance of connectors can be divided into three categories: mechanical performance, electrical performance and environmental performance.
Mechanical performance
In terms of connection function, plugging and unplugging force is an important mechanical performance. Plug-in force is divided into insertion force and extraction force (extraction force is also called separation force), and the requirements of the two are different. The relevant standards have provisions for maximum insertion force and minimum separation force, which shows that from the perspective of use, the insertion force should be small (thus there are low insertion force LIF and no insertion force ZIF structures), and if the separation force is too small, it will affect the reliability of contact.
Another important mechanical performance is the mechanical life of the connector. Mechanical life is actually a durability indicator, which is called mechanical operation in the national standard GB5095. It is based on one insertion and one extraction as a cycle, and whether the connector can normally complete its connection function (such as contact resistance value) after the specified plug-in and unplug cycle is used as the basis for judgment. The plug-in force and mechanical life of the connector are related to the contact structure (positive pressure size), the quality of the contact part coating (sliding friction coefficient) and the contact arrangement size accuracy (alignment).
Electrical performance
The main electrical performance of electrical performance connectors include contact resistance, insulation resistance and dielectric strength.
①Contact resistance High-quality
Electrical Connectors should have low and stable contact resistance. The contact resistance of connectors ranges from a few milliohms to tens of milliohms.
②Insulation resistance is an indicator of the insulation performance between
Electrical Connector contacts and between contacts and housings, and its order of magnitude ranges from hundreds of megohms to thousands of megohms.
③Dielectric strength, also known as withstand voltage or dielectric withstand voltage, is the ability to withstand the rated test voltage between connector contacts or between contacts and housings.
Environmental performance
Common environmental performance includes temperature resistance, moisture resistance, salt spray resistance, vibration and impact resistance.
①Heat resistance The current maximum operating temperature of connectors is 200℃ (except for a few high-temperature special connectors), and the minimum temperature is -65℃. Because the current generates heat at the contact point when the connector is working, resulting in temperature rise, it is generally believed that the operating temperature should be equal to the sum of the ambient temperature and the contact temperature rise. In some specifications, the maximum allowable rise of the connector at the rated working current is clearly specified.
② Moisture resistance The intrusion of moisture will affect the insulation performance of the connection and corrode metal parts. The constant humidity and heat test conditions are 90%~95% relative humidity (up to 98% according to product specifications), temperature +40±20℃, and the test time is at least 96 hours as specified by the product. The alternating humidity and heat test is more stringent.
③ When the salt spray resistant connector works in an environment containing moisture and salt, its metal structural parts and contact surface treatment layers may produce electrochemical corrosion, affecting the physical and electrical properties of the connector. In order to evaluate the ability of electrical connectors to withstand such environments, a salt spray test is specified. It is to hang the connector in a temperature-controlled test chamber and spray a sodium chloride solution of a specified concentration with compressed air to form a salt spray atmosphere. The exposure time is specified by the product specification and is at least 48 hours.
④ Vibration and shock resistance Vibration and shock resistance are important properties of electrical connectors, especially in special application environments such as aviation and aerospace, railway and road transportation. It is an important indicator for testing the robustness of the mechanical structure of electrical connectors and the reliability of electrical contact. There are clear regulations in the relevant test methods. The peak acceleration, duration and impact pulse waveform, as well as the time of electrical continuity interruption should be specified in the impact test.
⑤ Other environmental performance According to the use requirements, other environmental performances of electrical connectors include sealing (air leakage, liquid pressure), liquid immersion (resistance to degradation of specific liquids), low air pressure, etc.
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