System design engineers have begun to design and construct pre-tested modules, and then superimpose or blind plug them as a main construction technique. This requires femto-level interconnect devices. Manufacturers in the medical industry and even the military/aerospace industry are pushing systems to develop in this modular direction to meet the reduction in size, weight, and current required by complex signals. To meet these challenges, new connector designs must meet the combined requirements of enhanced electrical performance and durability and reduce the size and weight of the interconnection system.
Size and weight advantage
Improved machining and molding equipment and materials have been able to further reduce the size of the connector in structure. Although the size and weight of the two meet MIL-PRF-83513, the 21-position nano-connector weighs only 0.4g compared with the equivalent miniature D-shaped connector weighing 2.60g. In addition, 37-position micro D-shaped connectors require 4 times more space than 37-position board mounting or printed board connectors.
The choice of design and material is the key to successful size reduction. The core of the design is the elastic pin. To form high contact strength, low contact resistance, and maintain performance in thousands of plugs and unplugs, beryllium copper materials with special tensile annealing properties must be used. The main specifications of the thickness, length and shape of beryllium copper can ensure the long life and long performance of the miniature connector pins.
Most of the insulating shell is injection molded liquid crystal polymer, and some old designs use polyphenylene sulfide. When the 0.025" pitch makes the insulator between the pins only 10-11 mils, this type of insulating material still has high retention and high electrical insulation strength. The high-reliability PogoPin connector body can be used for plug-in and low-vibration The application is made of insulating materials, but most high-vibration and high-impact applications require a metal housing.
Durability depends on good installation design. Force and acceleration are key factors for testing the strength of PogoPin connectors in harsh applications. Due to the reasonable mounting bracket, the nano-PogoPin connector can pass vibration and shock of more than 10000Gs, such as under fire and launch conditions.
Nano circular connector
Compared with the nano-circular PogoPin connector, the micro-circular connector (0.050" pitch) is very large. When the pins and sockets with a pitch of 0.025" are installed, they can be used in the same circular area Up to 4 times as many interconnect devices. The current of the new circuit is mostly required to be less than 1A, because the digital processing enables the use of smaller wire gauge wires in the cable assembly to adapt to the nano circular connector. Therefore, the total weight and diameter of the interconnection system are greatly reduced. An additional benefit of nanocables is increased flexibility, because cables with smaller diameters are easier to route in tightly restricted locations.
According to the application, there are many types of nano-circular connectors. The metal-shell nano-circular connectors are the most durable, with excellent strain relief and handle mechanism. They are equipped with 360 seals for shielded cables and are environmentally sealed to prevent impregnation. Generally, they are used to connect remote detectors, sensors, and instrumentation to the front panel of the device. Nano-circular connectors are molded or installed into the system engineer’s own instrument. This method saves most of the space and allows the device or detector to have its own complete motor and mechanical connectors.