It is suitable for connecting straight and bent horn sockets, simple horn sockets and flat crimp sockets with flat cables. The flatcable connector is mainly realized by three parts, namely the pin seat, the crimping connector and the cable.
The main needle pitches are 2.54 mm, 2.00 mm, 1.27 mm; double-row form. The projection on the plug and the positioning groove on the needle seat have the function of preventing mis-insertion.
1. Cable selection
The cross-sectional size, toughness and flexibility of the cable should provide sufficient safe current load capacity and strength. Generally, it is not appropriate to use too thin wires.
2. Selection principle
The horn-type flatcable connector has horns, which takes up a lot of space, and the current usage level is generally less than 2A. When selecting, full consideration should be given to the structural requirements.
Simple horns are easy to loose due to the lack of buckle connection, and take up less space, but are not recommended for applications in vibrating environments.
It is recommended to choose a needle seat and plug with anti-insertion device.
Sunkye is a qualified connector manufacturer company and supplier, who support many flat cable connector types for a complete range of high-performance applications. A wide variety of mil dtl 83513 micro d connectors options are available to you, feel free to contact us.
Sunkye is uniquely qualified to deliver turnkey custom solutions and Mil-Spec connectors manufacturer for a complete range of high-performance applications.
The basic structural parts of the micro electrical connectors are ① contact parts; ② insulation parts; ③ shells (depending on the variety); ④ accessories
1. Contacts:
It is the core part of the structural cable connector to complete the function of military grade electrical connectors. Generally, the contact pair is composed of a male contact and a female contact.
The male contact is a rigid part and its shape is cylindrical (round pin), square post (square pin) or flat (pin). The male contact is generally made of brass or phosphor bronze.
The female contact is the key part of the contact pair. It relies on the elastic structure to elastically deform when mating with the pin to produce elastic force to form close contact with the male contact to complete the connection. There are many types of jack structures, including cylindrical (split groove, necked), tuning fork type, cantilever beam (longitudinal slot), folded type (longitudinal slot, 9-shaped), box shape (square socket) and hyperboloid wire spring jacks.
2. Insulator:
Insulators are often called base or inserts, and their role is to arrange the contacts in the required position and spacing, and to ensure the insulation performance between the contacts and between the contacts and the housing. Good insulation resistance, voltage resistance and easy processing are the basic requirements for selecting insulating materials for processing into insulators.
3. Shell:
She11 is the outer cover of the military spec connector. It provides mechanical protection for the built-in insulation mounting plate and pins, and provides alignment when the plug and socket are mated, so that the structural cable connector is fixed to the device.
4. Attachments:
The accessories are divided into structural accessories and installation accessories. Structural accessories such as collars, positioning keys, positioning pins, guide pins, coupling rings, cable clamps, seals, gaskets, etc. Installation accessories such as screws, nuts, screws, spring coils, etc. Most of the accessories are standard parts and universal parts.
Sunkye is a global solutions provider of d sub connector solutions and differentiated products to the world-wide interconnector industry.
PEEK connector, we also call it PEEK sealing terminal or HTHP connector, just as its name implies which the connector is made from PEEK material combining with metal contact and using glass sintered technology sealing PEEk material & contact so it has perfect air leakage performance. In wellhead, the gate valve requires to PEEK terminal for sealing, or tubing head spool for the connect gauge or control line of the outlet of the wellhead, and using on adapter spool for hydraulic control line terminated(C/L), electrical cable fit.
The working environment of the oil gas petrochemical industry always is harshness, dirty, high pressure, extreme temperature, chemical corrosion, low PH erosion, and various different kinds of gas. PEEK, benefits of physical performance with Pressure in 30,000PSI /207Mpa, the extreme temperature in 300℃, it satisfies for the special area and high-performance solutions.
PEEK melts at a relatively high temperature (343°C / 649.4°F) compared to most other thermoplastics. In the range of its melting temperature, it can be processed using injection molding or extrusion methods. It is technically feasible to process granular PEEK into filament form and 3D printing parts from the filament material using fused deposition modeling – FDM (or fused filament fabrication – FFF) technology. PEEK filaments have been demonstrated for producing medical devices up to class IIa. In its solid state PEEK is readily Machinable, for example, by (CNC) milling machines and is commonly used to produce high-quality plastic parts that are thermostable and both electrically and thermally insulating. Filled grades (30% Glass filled) of PEEK can also be CNC machined, but special care must be taken to properly manage stresses in the material. PEEK is considered a high-performance polymer, that is to say, its high price restricts its use to the most demanding applications only.
What is PEEK?
Polyether ether ketone (PEEK) is a colorless organic thermoplastic polymer in the polyaryletherketone (PAEK) family, used in engineering applications.
PEEK is a thermoplastic semicrystalline with excellent mechanical and chemical resistance properties that are retained to high temperatures. PEEK has a glass transition temperature of around 143 °C (289 °F) and melts around 343 °C (662 °F). That’s why PEEK seals and manifolds are commonly used in fluid applications. PEEK also performs well in applications where continuous high temperatures (up to 500 °F/260 °C) are common. It has high resistance to halogen, strong bronsted and Lewis acids, thermal degradation, biodegradation, Air leak: helium leak test ≤ 1× 10 -3 Pa.cm 3 /s
Because of its robustness, PEEK is used to fabricate items used in demanding applications, including bearings, piston parts, pumps, High-performance liquid chromatography columns, compressor plate valves, and electrical cable insulation. It is one of the few plastics compatible with ultra-high vacuum applications.
Beware of the difference of PEEK & PEK;
PEEK is Polyether ether keton & PEK is Polyether keton, both are very strong mechanical and chemical resistance properties but PEEk has one more molecule that means the physical performance more stability.
Avionics connectors (also known as aviation plugs) are named for their initial use in aviation. It is widely used in navigation, aerospace, aviation, national defense, military, nuclear industry, electric power and other fields. Magnesium-aluminium alloy and stainless steel are often used in the shell material, which is durable.
From a technical point of view, there are only three basic ways to classify military grade connector categories:
(1)There are threaded connection, clamp (fast) connection, lock connection, push-pull connection and straight insertion connection according to connection mode.
(2) According to shape: circular and rectangular (cross section)
(3) According to working frequency: low frequency and high frequency (bounded by 3MHz).
There are usually three types of technical parameters for aviation electrical connectors:
(1) Electrical Performance: Rated Voltage, Rated Current, Contact Resistance, Voltage Resistance and Insulation Resistance, Shielding, Radio Frequency Anti-interference Attenuation Value
(2) Mechanical properties: contact number and pinhole, installation mode and shape, shell material, insulator, contact, mechanical service life, etc.
(3) Environmental technical performance of avionics connectors: working temperature, working height, vibration, impact, constant acceleration, sealing, anti-salt fog, moisture-proof, anti-mildew performance, etc.
Sunkye is a qualified mil spec military connector 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.
100% Scoop- -proof to ensure no damage to the contacts in a blind mating application
With grounding reeds to strengthen emi/rfi shielding
Excellent performance of shock & vibration resistance
Good performance of fluid resistance
Widely used in aerospace, aviation & military system, especially for high impact vibration environment
MIL-DTL-38999 (formerly mil dtl 38999 wiki) describes four series of miniature, high density, bayonet, threaded, or breech coupling, circular, environment resistant, electrical connectors using removable crimp or fixed solder contacts, and are capable of operation within a temperature range of -65 to +200 degrees Celsius. Series III connectors are suitable for blind mating areas, and provide high-vibration characteristics at elevated temperature and are suitable for SWAMP areas with the proper connector accessories; (https://en.wikipedia.org/wiki/U.S._Military_connector_specifications)
Mechanical Performance of Sunkye MIL-DTL-38999-iii Connector
Sinusoidal Vibration : 10-50Hz, speed 254mm/s
50-140Hz, double -amplitude 1.5mm
140-2000Hz, acceleration 588m/s²
Random Vibration : high temperature 96(m/s²)²/ Hz 408m/s²,100~1000Hz
Random Vibration : environment temperature480(m/s²)²/ Hz,100~300Hz
Shock : 2940m/s² 3ms
Durability : 500 mating cycles
Contact Retentivity (Min.):
#22D : 44N
#20 : 67N
#16 : 111N
#12 : 111N
#8 coaxial : 111N
#8 triax : 111N
Mil-DTL-38999 Series III connector is a high-performance cylindrical connector that is designed for both general purpose and harsh environment applications. It adopts an enhanced “one turn” coupling system and self-locking screw thread to improve the durability of the coupling system, while the thicker wall and larger coupling surface area increase the strength and impact resistance. 38999 Series III connector can also be used for various shell materials and finishes (anode, zinc cobalt, aluminum, electroless nickel plating, olive cadmium, etc.).
For more information about MIL-DTL-38999 Series III connectors, click the “PDF Download” button above to see the details in the PDF file. If you have any difficulty searching for products, please contact us and Sunkye will help you find the best components for your application.
The high temperature and high pressure electrical connectors are designed to support the signal transmission of high voltage rating, and there is no safety risk for operators. In the design of connection system, the high pressure electrical connectors shall have 360° shielding layer and be effectively connected with the cable shielding layer, which covers the whole connector length to ensure sufficient shielding function and minimize the resistance between shielding interfaces.
Sunkye Nano sealed connector series features gold alloy Twist Pin contacts, Glass-sinter sealed can withstand high temperature and high voltage.
The nano circular connectors can meet oil exploration and other harsh environment applications. This series products widely applied in the military, land ground defense, air or areas.
Furthermore, Sunkye fully tests its hermetic Nano-D solutions to provide reliability and satisfaction to its customers. Helium leak rate is the most common and most reliable method to quantify a small leak. Based on its expertise, Sunkye can also design tailor-made nano circular connectors to fit your application needs.
Hermetic sealed PCB connector are used in applications where an enclosure needs to be isolated from the outside environment. Panel feed-through is the main application for this type of connector. In the vast majority of applications, the use of a hermetic encapsulate offers sufficient levels of hermeticity at a reasonable price. Only extreme environments require glass-to-metal sealing.
Description of MIL-DTL-83513 Twist Pin Plug Contacts
Sunkye MIL-DTL-83513 Micro D sub connectors fitted Twist Pin Contact System, offer outstanding mating performance, provides a superior wire attachment which translates to lower contact resistance—and it does so under extreme conditions of vibration, shock, and high heat. With 1.27mm contact spacing (pitch size), which is half the size of D-sub connectors allow for weight saving, which widely used in the military area, aerospace, aviation, electrical, ship-building, defense system, etc.,
The Twist Pin contact by its design and performance enables the system to meet the most severe requirements – often significantly more so than stipulated in the MIL-DTL-83513 and MIL-DTL-32139 standards. The male Micro-D contact is made up of 10 strands of beryllium-copper and copper alloy twisted together, welded then bumped. These sprung strands are in fact compressed during insertion into the turned female contact and therefore a high number of electrical contact points are permanently assured while retaining flexibility and ease of insertion/ extraction. The bulged point will be compressed inside the socket during insertion. Insertion and retention performance of the twist pin and socket mated pair. Both socket contact chamfer and twist pin hemispherical radius contribute to ensuring adequate insertion even in case of misalignment.
Producing MILDTL 83513 contacts, Sunkye has teamed of twist pin Technology with these custom designed insulators capable of meeting the extreme mechanical and electrical needs in the harshest environments of military/aerospace and industrial applications such as Down Hole Directional Drilling.
Product Offerings of MIL-DTL-83513 Twist Pin Plug Contacts
Full harnessing capabilities ranging from simple point-point to complex with many branches
Custom configurations and modifications Available to fit unique packaging and design requirements combine the twist pin performance with an increased temperature range
Beryllium copper (BeCu) wire strands provide seven points of electrical contact
Achieve high mating cycles and better resistance to shock and vibration
Approved system applications (Aerospace, Defense and Geothermal)
Miniature high-performance twist pin connectors
Performance of MIL-DTL-83513 Twist Pin Plug Contacts
The Sunkye family of TwistPin equipped microminiature d connectors to offer outstanding mating performance, durability, and minimal contact resistance. Sunkye Microminiature-D Connectors feature high-density micro TwistPin contacts set on 1.27mm centers in arrangements from 9 to 130 contacts. They are available with insulated and uninsulated wire, PCB, solder cup and flex terminations and are supplied as MIL-DTL-83513 or commercial variations. Our 83513 Micro-D high density connectors and COTS connectors provide a reliable solution for all high-performance interconnect requirements including high temperature and hermetic applications.
Description of MIL-DTL-83513 Micro D Connectors
By its very design, the Micro-D type connector system meets all the requirements of robustness, durability, low contact resistance, high current, dielectric strength, shock, and vibration. With 1.27 mm (.050″) contact spacing, Micro-D connectors, half the size of D type connectors (D series connectors), represent an excellent solution for saving both space and weight. In addition to a complete range of Micro-D connectors to 83513 micro D connectors, Sunkye also offers Micro-D PCB connectors and cable assemblies in both metal and plastic bodied versions. With its many possible configurations, the technology of micro electrical connectors is perfectly suited to a multitude of systems where weight, miniaturization or signal transmission integrity is paramount: applications benefiting from this technology include everything from missiles and their guidance systems, through oil well drilling tools to medical devices, satellites, and scientific research. For very specific applications such as medical MRI scanners or low magnetic field detection systems, Sunkye has developed a range of non-magnetic connectors using new materials and surface treatments, avoiding ferromagnetic materials. Hermetic micro d connectors are also offered for applications where an enclosure needs to be fully sealed from the outside world.
By the unique design and performance, Sunkye micro d connectors equipped with twist pin contact is enabled to meet the most severe requirements, often significantly more so than stipulated in the MIL-DTL-83513 and MIL-DTL-32139 standards. The male micro D contact is composed of 10 strands of copper alloy and beryllium-copper twisted together, which is welded then bumped. A high number of electrical contact points are permanently assured while retaining flexibility and ease of insertion/ extraction, because during insertion into the turned female contact the 10 sprung strands are compressed. To keep insertion and retention performance of the twist pin and socket mated pair, the bulged point will be compressed inside the socket during insertion. Meanwhile, the exit of socket contact chamfer and twist pin hemispherical radius ensures adequate insertion even in case of misalignment.
Range of Micro-D connectors which is covered by the MIL-DTL-83513* standard is ideally suited to equipment and applications where weight, miniaturization and long term performance are required, so in these aspects it is a model recommended by micro d connectors manufacturers. It is available: In 10 contact arrangements (9 to 100 contacts) for rectangular Micro-D connectors.
Frequently asked questions about Mil Dtl 83513 Micro D Connector
What is mil dtl 83513 Specification?
MIL-DTL-83513, (formerly MIL-C-83513) describes polarized shell, micro-miniature, rectangular electrical connectors with solder or non-removable crimp contacts. Featuring of high current capability, low contact resistance, high dielectric strength and excellent resistance to shock and vibration, while offering a high pin density, small size and lightweight body, the MIL DTL 83513 connector meet the severe requirements of different applications and harsh environments, which is mechanically robust and durable. The connector is often referred to as a Micro-D connector system, which can be applied to a multitude of systems including aerospace avionics, radars, advanced soldier technology systems, military Global Positioning Systems, medical devices and down-hole drilling tools, etc., in which weight, miniaturization or signal transmission integrity are paramount. The Micro-D formfactor has become so popular among engineers and systems designers that many manufacturers have begun to offer high speed (up to 10Gbps) and modular versions of the connector.
What is a micro D connector used for?
The D-subminiature or D-sub is a common type of electrical connector commonly used in computers, Communications ports, Network ports, Game controller ports, etc. D-sub connectors feature parallel rows of connector pins, surrounded by a metal shield. The shield is shorter on one side, resembling the D English letter. A smaller type of connector derived from the D-sub is called the microminiature D, or micro-D. It is about half the length of a D-sub and its primary application is space-grade technology.
Except MIL DTL 83513, What are other Mil Spec Connector?
Mil Spec connector are now used in aerospace, industrial, marine, and even automotive commercial applications. For electrical connectors, except MIL DTL 83513, there are many Military Standards including MIL DTL 32139, MIL DTL 38999, MIL DTL 26482, MIL-DTL-83538 standard, etc. For fiber optic connectors, there are two main standard: MIL-C-83522 and MIL-DTL-83526. For alternative connectors, MIL-PRF-29504, MIL-PRF-2887, MIL-PRF-39012, MIL-PRF-31031, MIL-PRF-49142, MIL-PRF-64266 are widely used.
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