December, 2015
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Robust Interconnect Solutions for Reliability Continued from page 58
tions and extractions — as well as stationary mating scenarios where a connection faces extended exposure to harsh conditions such as shock and vibration. Typically, high quality interconnects are able to withstand 15-G vibration and 50-G shocks with no electrical discontinuity greater than 1µs. High-reliability receptacles are
well-suited for socketing sensitive devices such as gas detectors, trans- ducers used in seismic recorders, temperature and pressure sensors like those found in downhole and underwater exploration as well as inspection equipment and robots. Bulb sockets often utilize these types of high-precision receptacles, partic- ularly in safety equipment such as flashlights and lamps used by the military, law enforcement, firefight- ers, and the mining industry. With the likelihood of high shock and vibration events, rugged environ- ments also call for dependable con- nections and precision receptacles for applications as diverse as the fir- ing mechanism of smart bullets, military radios, sighting scopes, field data recorders, ruggedized computers, sockets for aerospace dashboard displays, and nail guns for construction. While beryllium copper is the
default material for standard inter- nal spring contacts for receptacles, applications that are exposed to high temperatures can take advantage of more temperature- and force-resist- ant materials. For applications such as downhole oil and gas exploration or test and burn-in systems, where the ambient temperature is above 150°C (302°F), beryllium nickel is the material of choice for contacts. Beryllium nickel exhibits little or no stress relaxation when exposed to a temperature of 225°C (437°F) for 1,000 hours. Along with high-tem- perature performance, beryllium nickel contacts also inherently with- stand high forces.
Interconnect Flexibility In more advanced interconnect
systems, beryllium nickel contacts fit into the same receptacle shell as their beryllium copper counterparts and can be specified as a design evolves from the workbench to the field. With more sophisticated inter- connect solutions available, engi- neers can test their designs, modify strategies, and even switch to differ- ent connector materials and sizes
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without having to redesign the entire system. For applications requiring opti-
mal environmental protection, or for PCB press-fit applications, gold plat- ed shells and contacts are a good choice. Because both the outer shell and internal contacts are individual- ly plated, the design engineer has the flexibility of choosing tin, tin/lead, gold, or silver plating based on eco- nomic and engineering considera- tions. For example, tin or tin/lead plated shells with gold-plated inter- nal contacts are a cost-effective option for solder mount receptacles that accept gold-plated mating leads. Despite the different combinations of metals, the gas-tight press-fit be -
tween the contact and shell elimi- nates the chance of oxidizing interac- tions. This connection ensures that no corrosion arises at the contact shell junction due to humidity or exposure to gases. Mill-Max’s interconnect plat-
forms allow designers to change pin sizes due to the wide mating lead acceptance range built into the com- pany’s products, which range from about 0.01 to 0.02 in. (0.25 to 0.51 mm). If a piece of equipment is designed to receive a cable of a par- ticular size, and that cable is revised to use larger or smaller pins, the wider acceptance range available in a versatile design may easily support the change in specifications.
Page 61 Interconnect quality and relia-
bility plays a fundamental role in determining overall system quality and reliability. For designers, highly developed interconnect systems pro- vide a broad array of solutions, preci- sion-machined from alloys, designed to meet varying needs for ductility, manufacturability, strength, and temperature resistance. Drawing on these precision parts, engineers can create a solution tailored to the requirements of each application. r Contact: Mill-Max Mfg.
Corporation, 190 Pine Hollow Road, P.O. Box 300, Oyster Bay, NY 11771 % 516-922-6000 fax: 516-922-9253 E-mail:
rritter@mill-max.com Web:
www.mill-max.com
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