Selecting the Ideal Contacts for Your Connector
Demystifying Connector Contacts: A Comprehensive Guide
Choosing the right electrical contacts for your connectors can be a complex task. This guide simplifies the process by explaining key factors to consider and providing valuable insights.
BonChip Electronics, as a leading distributor of electronic components, offers a wide range of connectors and contacts from various manufacturers, including Souriau. We understand the importance of selecting the right components for optimal performance, and our expert technical support team is here to assist you throughout the process.
Understanding Electrical Contacts
Electrical contacts are the heart of any connector, forming the physical connection between pins and sockets. They come in various shapes, sizes, and types, each catering to specific applications. Here's a breakdown of the two main types:
- Signal Contacts: Designed for transmitting low-level electrical signals, typically in applications like sensors and buttons. These contacts are smaller (#20, #16) due to the lower current and voltage requirements (a few mA to a few A).
- Power Contacts: Built for transferring higher voltage and current to power components and equipment. They are larger (#12, #8) compared to signal contacts to accommodate these demands. Industrial power contacts can handle currents up to several dozen amps.
Important Note: Smaller contact numbers denote larger sizes (e.g., #8 is larger than #20).
Choosing the Right Contacts
Contacts packaged in bulk
Several factors influence contact selection. Here's a step-by-step approach to guide you:
Step 1: Analyze Your Requirements
- Current and Voltage: Determine the amperage and voltage your circuit will carry. This dictates the compatible connector and contact size. Remember, the connector's current carrying capacity is crucial. More contacts within a connector generate more heat, potentially exceeding the connector's operating temperature and damaging your system. Consider the connector layout – increasing the number of contacts within the same space raises heat generation. Choose the balance between electrical needs and the connector's current rating.
Step 2: Wire Size
Match the contact size to your existing wires. If your wires are AWG size 8 or 10, you'll need #8 contacts as smaller contacts wouldn't accommodate them. Refer to contact size tables for specific compatibility information.
Step 3: Contact Type
- Machined Contacts: Preferred for power applications, low-volume orders, or heavy-duty use.
- Stamped and Formed Contacts: Suitable for high-volume production due to compatibility with automated crimping machines.
Industry standards in specific sectors like aerospace and railway might mandate machined contacts.
Step 4: Delivery Options
Contacts can be delivered loose in bulk or loaded on reels. Machined contacts are typically loose, while stamped and formed contacts come on reels. This choice depends on your setup and crimping equipment. Avoid crimping reel-mounted contacts with hand tools, as it can compromise quality.
Step 5: Plating
Plating affects conductivity, durability, and cost of contacts:
- Smaller Contacts (#20, #16): Typically plated with at least 0.4 µm of gold for excellent conductivity and durability (suitable for numerous mating cycles). However, gold is expensive.
- Slightly Larger Contacts: Often use tin plating, a cost-effective option for static or low-vibration environments.For higher vibration or frequent mating cycles, gold flash plating is preferred for enhanced reliability.
- Larger Contacts (#12, #8): Silver plating offers the best balance between cost and performance.
Conclusion:
By considering these factors, you can make informed decisions when selecting contacts for your connectors:
- Identify your wire size to determine compatible contacts.
- Choose the appropriate connector and layout.
- Select machined or stamped and formed contacts based on performance needs and crimping setup.
- Decide between bulk or reel-mounted contacts based on your equipment.
- Choose the optimal plating material based on your application's performance requirements.
For further assistance or questions, contact the technical and commercial teams at BonChip Electronics.
