December, 2015


www.us- tech.com


Page 57


Robust Interconnect Solutions for Reliability T


By Stephen Capitelli, Manager of Product Engineering, Mill-Max Mfg. Corp.


he quality and reliability of an interconnect directly influence system performance and reliability. The impact of an interconnect is


often appreciated only when poorly manufactured or incorrectly specified connectors fail, erode sys- tem performance, or bring the system to a com- plete halt. For designers, advances in connector design, materials and manufacturing ensure avail- ability of an interconnect solution that is well- matched to each individual application. The selection of a suitable connector depends


on a design’s particular performance require- ments, configuration limitations, operating condi- tions, and working environment. For example, the connector requirements for a healthcare applica- tion are dramatically different from those for a deep mining application, and yet each require the connector to be reliable.


High Precision Construction Today’s connectors are high-pre-


cision pieces, carefully designed and manufactured using a variety of high- ly conductive alloys, application-spe- cific platings and high temperature, high strength housing materials. One of the main components of


connectors and discrete interconnect systems is the pin receptacle. Pin receptacles are made by press-fitting stamped and formed “multi-finger” precision contact clips into a machined shell. This style of contact has proved to be a reliable and con- sistent method of connecting critical components.


Manufacturing and Materials The receptacle itself is a product


of precision machining and special- ized alloys designed to match specific application necessities. For precision connector lines, high-speed Swiss turning and CNC machines produce parts across a wide range of sizes while holding very tight diameter tol- erances of ±0.0005 in. (0.013 mm) and even tighter for some applica- tions. Internal stamped finger con- tacts provide connections for mating leads ranging in diameter from 0.008 to 0.102 in. (0.2 to 2.59 mm) as well as in square and rectangular pins. Precision manufacturing allows


for a wide range of shapes and sizes, but the materials used for intercon- nect manufacturing give these parts


Connectors play a critical


role in electrical systems of just about any product.


However, the interconnect requirements are frequent- ly considered at the end of a product design phase.


specific characteristics for different requirements. A variety of alloys are used in the creation of machined elec- trical interconnects — mainly copper- based due to copper’s high conductiv- ity. Other materials include highly ductile brass and high-strength beryllium alloys. Brass is most commonly used


because of its excellent machinabili- ty, is suitable for a wide variety of applications, and is less expensive than other materials. Phosphor bronze is a more ductile material; useful when additional strength and bending resilience are required. For higher current applications, the high conductivity of tellurium copper (93


Pin receptacles combine a shell with a clip for a gas-tight connection.


percent IACS at 20°C/68°F) provides a low-resist- ance electrical path and produces less rise in tem- perature. Depending on the desired size and force char-


acteristics, the internal contacts are three-, four-, or six-finger designs stamped from either berylli- um copper alloy C17200 (HT) or beryllium nickel alloy 360. Beryllium copper has emerged as the standard for the majority of applications due to its excellent strength, spring characteristics, durabil- ity, and conductivity. Beryllium nickel exhibits similar properties and is particularly suitable for use in high-temperature environments above 150°C (302°F).


Continued on next page


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