As an important electrical connection component, SMA radio frequency connector plays a pivotal role in various electronic equipment, instruments, and electronic information systems. After decades of development, RF coaxial connectors have formed an independent and complete professional system and become an important part of the connector family.

In addition to pursuing the two key technical projects of miniaturization and high frequency, electrical connector manufacturers are also constantly improving the multi-function and reliability of their products. Nowadays, RF connectors not only serve as signal connection, but also have signal processing functions, such as filtering, phase modulation, mixing, attenuation, detection, and amplitude limiting. In addition, low standing wave, low loss, large capacity, high power and ease of installation have also become the goals of manufacturers’ efforts.

The basic parameters of SMA SMT connector
Insulation resistance refers to the resistance value exhibited by applying voltage to the insulating part of the connector, so that leakage current is generated in or on the surface of the insulating part. It is mainly affected by factors such as insulation material, temperature, humidity, and contamination. The insulation resistance value provided on the connector sample is generally an index value under standard atmospheric conditions. Under certain environmental conditions, the insulation resistance value may drop to an unused degree.

1. Safety parameters
   Insulation resistance refers to the resistance value exhibited by applying voltage to the insulating part of the connector, so that leakage current is generated in or on the surface of the insulating part. It is mainly affected by factors such as insulation material, temperature, humidity, and contamination. The insulation resistance value provided on the connector sample is generally an index value under standard atmospheric conditions. Under certain environmental conditions, the insulation resistance value may drop to an unused degree. Also pay attention to the test voltage value of the insulation resistance. Depending on the insulation resistance (MΩ) = voltage (V) applied to the insulator (V)/leakage current (μA), applying different voltages will have different results. In the test of milspec connectors, the applied voltage is generally 10V, 100V, and 500V.
2. Withstand voltage
   Withstand voltage is the critical voltage that can withstand higher than the rated voltage within a specified time between the mutually insulated parts of the contact pair or between the insulated parts and the ground without causing breakdown. It is mainly affected by contact spacing and creep age distance and geometry, insulator materials, ambient temperature and humidity, and atmospheric pressure.

3. Flammability

Any connector is inseparable from current when it is working, so there is a risk of fire. Therefore, the mil connector is required not only to prevent ignition, but also to self-extinguish in a short time once it ignites and catches fire. When choosing, pay attention to choosing electrical connectors that use flame-retardant, self-extinguishing insulating materials.

Termination method of SMA SMT RF connector

1. Wiring type

Wiring is divided into welding wire type connectors and crimp style connectors. The wire bonding type is to weld the center conductor and the cable shielding layer. The crimping type is to crimp the center conductor and the cable shielding layer, and the crimping type has good efficiency and high performance. The wire bonding is stable and reliable. Generally, the crimping type is used for flexible cables, and the welding type is used for semi-flexible cables and half steel cables.

2. Connect to PCB (printed circuit board)

When the connector is to be connected to the PCB, it is mostly through hole or SMT. In order to facilitate tinning, the metal connecting with the PCB is mostly gold-plated or tin-plated.

3. Panel type

Panel connectors are mostly installed on the chassis to connect internal and external devices. The flange type is to drill holes on the main panel of the connector for installation and fixation. Another type is to machine screws on the main body of the connector and fix them with the screws. Such connectors often require waterproof functions.

The development trend of Sunkye SMA RF connectors will have the following characteristics:

1. Miniaturization: With the miniaturization of the overall system, the size of the RF connector is getting smaller and smaller.

2. High frequency.

3. Multi-function: In addition to the role of a bridge, it also has the functions of signal processing, such as filtering, phase modulation, frequency mixing, attenuation, detection, and amplitude limiting.

4. Low standing wave and low loss: meet the needs of weapon systems and precision measurement.

5. Large capacity and high power: Large capacity and high power mainly meet the development needs of the information highway.

6. Surface mount: Mainly meet the development needs of SMT technology (surface mount technology), and help simplify the wiring structure design of multilayer printed boards.

PRODUCTION PROCESS OF CONNECTOR CONTACTS

The structure of the contact parts varies according to the conditions of use and requirements.

The typical structure and process of the commonly used contacts:

1. Mechanical processing

(1) Slitting automatic lathe:

It is suitable for processing parts with complex geometric shapes and high surface quality requirements. And slender rod parts. A set of tooling such as cams and circlips is required for each type of part. Machine adjustment is more complicated

Suitable for medium batch or large batch

(2) CNC slitting automatic lathe processing method:

It is suitable for processing parts with complex geometry and high precision, for example, military style electrical connectors. Tune

It is easy to adjust and easy to replace parts. But the cost of machine tools is too high

Suitable for small batches

(3) Single-axis forming and cutting automatic lathe processing method:

Suitable for processing parts and raw materials with simple geometric shapes

Directly processed by disc-shaped silk material. The cost of machine tools is high. The tool quality and adjustment technical requirements are high.

Suitable for large batch or medium batch

(4) Multi-station disc material automatic machine tool processing method

Suitable for parts processing in large batches and continuous production for several months.

The disc-shaped silk material is formed by several or even dozens of processing steps.

The cost of the machine tool is very high, and the adjustment of the machine tool is difficult.

Suitable for extra large quantities

2. Stamping

(1) Multiple sets of mold forming methods

The lath material is punched and formed through multiple processes. The cost of the custom mil connectors mold is low, and the machining accuracy of the parts is not high.

Suitable for large quantities

(2) Progressive die forming method

It is suitable for the processing of punched parts or punched and bent parts. Mold costs are higher. High precision parts and good dimensional consistency.

Suitable for extra large quantities

3. Cold extrusion processing

(1) Multiple sets of mold forming methods

Low mold cost and low machining accuracy

Suitable for large quantities

(2) Combined mold forming method

High mold cost and high precision of parts processing

Suitable for large quantities

Sunkye is a qualified mil spec connectors manufacturer and supplier, who support custom connectors for a complete range of high-performance applications. A wide variety of military connector options are available to you, feel free to contact us.

There are many details in the use of joints that should be noted. If there is a disconnection during use, how should it be handled correctly?

First cut off the power cord from the root of the waterproof military connector, peel off the end of the cord, measure it with a multimeter, and then reserve the best.

Then carefully cut the power supply waterproof connectors marine from both sides with a saw, remove the waterproof connector copper piece, and you can see the broken place.

Remove the embroidering of the copper wire of the waterproof connector with sandpaper, and then solder the power cord to the copper. After welding, put it back into the sawed waterproof joint, seal it with epoxy resin, and fasten the waterproof joint with a small iron clip. It can be used after 24 hours of curing.

Pay attention to the following points when installing and using waterproof connectors and sockets:

1. The socket should be installed on an insulating board, in an insulating box, or on electrical boards and logs. Usually, the two holes of the socket are installed in parallel on the plane of the building.

2. When installing a three-hole socket, the grounding hole (large hole) must be installed above, and the grounding terminal must be connected to the grounding wire, and the neutral wire cannot be borrowed as the grounding wire.

3. The phase line should be connected to the specified terminal (marked with “L” letter). The 220v power supply enters the socket generally as “left zero right phase”. The sockets with both double holes and three holes are combined sockets, which are mostly used as mobile sockets. Its structure and installation are similar to double-hole and three-hole sockets.

4. The rated current of the waterproof connector or socket that meet the ip68 waterproof standard is greater than the rated current of the load of the connected electrical appliance, and the rated current of the electrical appliance is not allowed to exceed the rated current of the socket.

5. Use mobile plugs to keep clean, pay attention to moisture to prevent leakage or short circuit due to insulation damage.

6. Some single-phase three-eye plugs and sockets or three-phase four-eye plugs and sockets must connect the ground wire to the terminal with the grounding symbol when wiring, and connect with the metal shell of the electrical appliance to ensure the safety of electricity.

7. Plugs and sockets must be in firm contact during wiring. The metal ends of the wires on adjacent terminals must be kept at a certain distance, and no burrs are allowed to prevent short circuits.

Contact Sunkye for more info about Waterproof Connector.

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What Is Polytetrafluoroethylene PTFE?
Polytetrafluoroethylene (PTFE) is a synthetic fluoropolymer of tetrafluoroethylene that has numerous applications.

PTFE is a fluorocarbon solid, as it is a high molecular weight compound consisting wholly of carbon and fluorine. PTFE is hydrophobic: neither water nor water-containing substances wet PTFE, as fluorocarbons demonstrate mitigated London dispersion forces due to the high electronegativity of fluorine. PTFE has one of the lowest coefficients of friction of any solid. Also, trade name called Teflon.

PTFE is nonreactive, partly because of the strength of carbon-fluorine bonds, and so it is often used in containers and pipework for reactive and corrosive chemicals. Where used as a lubricant, PTFE reduces friction, wear, and energy consumption of machinery. It is commonly used as a graft material in surgical interventions. It is also frequently employed as coating on catheters; this interferes with the ability of bacteria and other infectious agents to adhere to catheters and cause

hospital-acquired infections which makes it perfect to be used in custom medical ptfe connector manufacturing.

Wire AFR250(PTFE) MIL-DTL-681 Datasheet & Specification

Wire AFR250(PTFE) Datasheet & Specification
Standard	MIL-DTL-681
Cross section	0.15m²
Conductor Construction	30pipes	D0.08mm/pipe
Insulation thickness	120VDC	0.10mm
	300VDC	0.15mm
	600VDC	0.25mm
Wire Diameter	120VDC	0.70mm
	300VDC	0.80mm
	600VDC	1.00mm
20℃ Conductor DC Current Insulation resistance	150Ω /km
Temperature	-65~250℃

MIL-DTL-681 NO.	PIN NO.	WIRE COLOR
0	1	BLK
1	2	BRN
2	3	RED
3	4	ORN
4	5	YEL
5	6	GRN
6	7	BLU
7	8	VIO
8	9	GRY
9	10	WHT

As a connector manufacturer company, we can offer kinds of d sub connector for sale, if you have needs, please contact us.

From the purpose of using automobile connector, in order to ensure better driving of the car, we can divide the reliability of the connector into the tightness of the connector in use, the performance of fire protection, the performance of shielding, and the performance of temperature control.

Generally speaking, when discussing the tightness of automotive power connectors, it does not only refer to the tightness to water. In this area, the current popular international management specification is IP67, and this specification is now the highest level in the automotive industry. Although the requirements for waterproofing are different in different parts of the car, many car manufacturers will choose IP67 to ensure the tightness of the connector of their car.

In the driving of a car, the power source is a very important energy source, which is not only related to the normal work of the engine, but also often involves the use of the power source when people are driving. So in the car’s power supply system, mil spec electrical connectors have different divisions. Certain sealing measures can be implemented between the male connector and the device, between the male connector and the cable, between the male and female connector, and between the female connector and the cable.

In the realization of the sealing performance of automotive connectors, the seal ring is a commonly used tool. This tool can not only achieve the effect of fixing between different hole positions, but also the effect of sealing. It can not only ensure the stable operation of automobile equipment, but also ensure the waterproof performance of automobile equipment in work.

In the production of seal rings, silicon rubber is mostly used. This material is made by liquid silicon and solid silicon after certain chemical changes.

Now that electronic circuit technology is an important aspect of the automotive industry. In order to ensure the stable operation of electronic circuit technology, people have applied many shielding technologies in the production of automobiles. These shielding technologies not only play a protective role in the electronic circuit of the car, but also play a role in anti-interference and anti-radiation in the parts of the car. In addition, they can also protect the stable operation of waterproof automotive connectors.

Shielding technology can be divided into two types: internal shielding and external shielding. When using an outer shield to protect an automotive connector, two identical shielding shells are usually assembled together to form a shielding layer, and the length of the shielding layer can cover the length of the entire connector. There is enough locking plate structure to ensure the reliable installation of the shielding layer. In addition, the shielding material used must not only be treated by electroplating, but also be treated to prevent chemical corrosion.

As a connector manufacturing company, we can offer kinds of mil spec connectors for sale, if you have needs, please contact us.

For military connector manufacturers, in addition to their productivity, they also care about product quality. When it comes to product quality, many aspects will be involved, such as the performance of high-speed micro-pitch interconnects for connectors.

In general, there are nine main methods to improve the high-speed micro pitch connectors:

1. Connector products, in the early stages of design, need to perform multiple simulation cycles to accurately quantify product performance before starting an expensive processing process.

2. When the military grade connector is mated, the stub in the contact area should be minimized. The longer the stub, the better the reliability, but the stub is an electrical load like an antenna.

3. Simplify contact geometry and improve signal path performance.

4. Shorten the pin length to minimize the distance that the signal must travel.

5. Add asymmetric footprints and contacts as much as possible, because the alternating design reduces pair-wise crosstalk between rows of pins and between rows. It can also be said that footprint should drive connector performance.

6. Optimize the connector branch area (BOR). Think of the connector as a key node in the link, not only focusing on the node, but also the link.

7. Where space permits, incorporate a common ground plane into the connector.

8. The choice of plastic molding will obviously affect the performance of military type connectors. These attributes should be carefully considered: high-temperature plastics suitable for RoHS, matching Dk to obtain the required impedance control, dimensional stability of temperature and time.

9. The shorter and straighter the contact between the signal path and the connector, the better its signal integrity. But the balance function is that the connector must have sufficient normal force and exit force, and it also needs to have a certain degree of robustness.

Sunkye International was originally developed in the early 1950’s and was one of the twist pin, mil grade connectors including mil spec micro D connector and mil spec nano D connector manufacturing companies to license this technology and improve it. Sunkye focuses on custom military connector assembly and standard Mil-Spec military connectors for quick turnaround to help you reduce your acquisition cost and lead times, simplify your assembly, and improve the quality and reliability of your military designs.

1. Select the electrical connectors listed in the list of qualified products published by the military components’ management center of the national defense science and engineering commission.

2. Select the electrical connection listed in the “preferred catalogue of electronic components of various models” of aerospace system engineering.

3. Select the quality grade reasonably.

4. Standard or general electrical connector shall be preferred, and non-standard or new electrical connector shall be used with caution.

5. Carry out delivery test and secondary supplementary screening.

6. Pay attention to the use reliability of electrical connector.

Reliability prediction of aerospace electrical connector

According to GJB/Z299B-98 “reliability prediction Manual of electronic equipment”, the following formula can be used for prediction.

λp=λb×πE×πQ×πP×πK×πC

Where: λp – working failure rate;

λb – basic failure rate;

πE – environmental coefficient;

πQ – mass coefficient;

πP – contact coefficient;

πK – plug coefficient;

πC – jack structure coefficient.

The U.S. military standard mil-hdbk-217e “reliability prediction of electronic equipment” can be predicted according to the following formula.

λp=λb×πE×πP×Nλcyc(3)

Where: n – number of working pins, λcyc can be ignored for electrical connector with insertion and extraction rate ≤ 40 times / 1000h.

Conclusion

A large number of statistical data show that about 70% of the quality defects of aerospace products belong to mil spec electrical connectors problems, and the remaining 30% belong to manufacturing, shipping and other problems. The design and development of aerospace products is the source of aerospace product quality. Therefore, it is very urgent to analyze the reliability of electrical connector in the design of aerospace products to improve the quality of aerospace connectors.

It is the undeniable responsibility of equipment departments, military enterprises and scientific research institutes to continuously improve the quality of aerospace products. The reliability analysis of aerospace d sub connector play an important role in identifying and eliminating potential quality defects of aerospace products. The reliability analysis of electrical connector can be done well in advance, which can easily change the design of aerospace products, thus reducing or eliminating the chance of greater damage caused by design. Timely reliability analysis of aerospace electrical connector will greatly improve the quality of aerospace products.

With the continuous development of electronic technology, in addition to the increasingly multi-functional, high-performance, intelligent, miniaturization (even portability) has become one of the most important and obvious features of the development of electronic equipment. The portability of electronic equipment requires that the size of the connector, which is the necessary component to form a complete system, should be reduced and the installation density is increased. Miniaturization plays an extremely important role in the development of connector industry.

In recent years, with the rapid development of electronic technology, products are constantly updated. Portable products are becoming more and more popular, which greatly promotes the development of miniature electrical connectors. The development of micro-connectors has reached a new stage. Micro miniature connectors are widely used in many fields, such as computer, communication equipment, industrial test instruments, military equipment and new electronic consumer goods, etc. All of these require micro-connector products to varying degrees.

Laptop computers have the greatest demand for micro-connectors. In the next ten years, notebooks and handheld computers will become the mainstream of PC. A portable notebook computer needs a large number of different types of micro connectors.

Connectors for communication equipment are also developing towards miniaturization. The main computers used for miniature waterproof connectors are pagers, mobile phones, etc. With the rapid development of modern communication technology, it is believed that micro-connectors will be more and more widely used under the new communication technology.

In the military field, due to the change of international situation, the market of military grade connector is shrinking, and the demand for micro-connectors may

slow down. However, adapting to the harsh use environment and high reliability requirements of military electronic equipment is the main driving force to promote the development of micro miniature wire connectors‘ technology. High-end micro miniature connectors products are often first used in aviation, modern military electronic equipment and new weapons and other sophisticated military equipment. It can be predicted that in the future, modern military equipment will still be one of the important fields of micro-connector research and development and application.

Sunkye is a qualified mil spec connectors manufacturer and supplier, who support custom connectors for a complete range of high-performance applications. A wide variety of military connector options are available to you, feel free to contact us.

As a connectors supplier, we will do our best to meet all the needs of customers.

Micro connectors are widely used in many fields, ranging from computers, communication equipment to industrial testing instruments. From military equipment to new electronic consumer goods, they all put forward varying degrees of demand for micro-connector products.

Laptop computers have the greatest demand for micro-connectors. In the next ten years, notebook computers and handheld computers will become the mainstream of PC. A portable notebook computer needs a large number of different types of micro-connectors, including components-substrate, overboard-substrate, subsystem-subsystem interconnection products such as IC socket, micro pcb connectors, D-Sub type connectors. Most of these products belong to micro-products with spacing less than 1.27mm.

The demand of application market promotes the continuous expansion of the market of various micro connector products. Micro pcb connectors, FPC connectors, circular connectors: rectangular connectors, IC sockets, coaxial connectors, etc. have been realized to varying degrees. Among them, PCB and IC socket connectors have the fastest growth rate. PCB connectors are mostly used for in-machine wiring. With the increasing portability of electronic devices, the requirement for miniaturization of different types of PCB connectors in the whole plant is increased, so there will be more and more micro pcb connectors in the market.

The development of connector miniaturization in various countries or regions is not balanced, but countries are also working towards higher goals.

Sunkye is a qualified mil spec military connector manufacturer and supplier, who support custom sunbank connectors for a complete range of high-performance applications. A wide variety of military connector options are available to you, feel free to contact us.

UAV

As UAVs play a greater role in military operations, the pressure to reduce volume and weight is also increasing. Aerospace UAV Connectors are an important basic component that is almost ubiquitous in military and aerospace aircraft & UAV applications and serve as interconnects for transmission signals and power, which has to meet stringent testing for outgassing and residual magnetism to be suitable for use in airspace & UAV applications. Outgassing and residual magnetism can adversely affect nearby components.

Weight & space-saving is necessary for aircraft & UAV cable connectors because there is only so much room on a space vehicle. They have to be extremely reliable as well and they must resistant to severe environmental conditions like shock, radiation, extreme temperatures, and vibration. In the case of high vibration, shock and temperature cycling, the board to board or box to box connectors of UAV and its cables must also be highly reliable.

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