INTERCONNECTION
Selecting Space-Grade Connectors for LEO Satellite Applications
By Rolf Horn T
he satellite industry is experiencing rapid growth, particularly in the area of low earth orbit (LEO) satellites. However, the challenges for designers. Exposure to a vacuum, atomic oxygen, intense ultraviolet (UV) radiation and extreme temperature degradation and connector failure, potentially compromising mission-critical systems. To ensure mission success, designers must understand the challenges of operating in space and select connectors from reliable sources that incorporate the advanced materials and technologies necessary to meet the demands of LEO conditions. designing for LEO applications and discusses strategies for mitigating the environmental effects. It then introduces appropriate connectors from Cinch Connectivity Solutions that can help meet these challenges.
Environmental challenges in LEO and their impacts on connectors
Designers of LEO satellites face unique environmental challenges. While the environment is not as harsh as deep space, LEO satellite connectors and other components must withstand outgassing, radiation and corrosion, temperature extremes, and vibration and shock.
1. Outgassing
Outgassing describes the release of gases from non-metallic materials when they are subjected to heat or a vacuum. It is a Plastics are widely used in connectors for their excellent insulating properties and some metals used in connectors may contain microscopic gas bubbles trapped during manufacturing. When connectors are manufactured at sea level, these gas bubbles are not subject to the forces applied by differences in pressure inside and outside the material.
6 APRIL 2025 | ELECTRONICS FOR ENGINEERS
However, in the vacuum of space, the releasing these trapped gases. This outgassing can lead to small cracks and the connector (Figure 1).
Outgassing can also damage sensors such as cameras by forming a coating layer. It may even lead to short circuits between connectors and components, jeopardising a mission.
While the vacuum of space primarily drives outgassing, other environmental factors can increase its likelihood. For example, the weakening of polymers caused by UV radiation and exposure to atomic oxygen make it easier for trapped gases to escape.
2. Radiation and atomic oxygen exposure Constant exposure to the sun’s UV radiation can damage plastics used in connectors. Ionising radiation can lead to charge accumulation on connectors, potentially causing electrostatic discharge events. Atomic oxygen, abundant in the LEO
environment and formed when UV radiation reacts with oxygen, is highly reactive and can erode connector materials, especially polymers and some metals. For example, plastic insulation material in connectors, reacts when exposed to atomic oxygen and UV radiation, leading to wear. Atomic oxygen is particularly reactive with silver, causing oxidation and impacting electrical conductivity and contact resistance.
LEO satellites experience temperature swings from 125°C in sunlight to -65°C in the Earth’s shadow, with some external components potentially facing temperatures from -270 to 200°C. This leads to thermal cycling, which stresses and can exacerbate minor imperfections in connectors. The differences between connector materials and associated components can result in uneven thermal cycling, leading to incompatible combinations and potential failure.
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