A brief analysis of the difference between sealed connectors and non-sealed connectors

A connector is a common component in electronic equipment that is used to connect circuits together so that current can be transmitted smoothly and ensure the normal operation of the equipment.

They are widely used in a variety of fields and offer features such as reliability, high-speed transmission, high-density connectivity and durability to support device performance and functionality.

When it comes to electrical connections in automotive and industrial environments, it’s important to understand the differences between sealed and unsealed connectors. This article focuses on the subtle differences between these two types of connectors.

Definition-and-application-scenarios

Definition and application scenarios

Sealed connectors are specially designed for electrical and signal transmission, and have sealing properties such as waterproof, dustproof, and anti-corrosion. They provide reliable connections in harsh environments and protect internal circuitry from the external environment.

Sealed connectors are widely used in automotive, aerospace, shipbuilding, military, industrial equipment, outdoor electronics and other fields. These applications have high requirements for connector sealing and reliability.

Non-sealed connectors have no sealing design, and the connectors are not specially treated to prevent liquid or dust from entering. Non-sealed connectors are usually used for internal slot connections in household appliances, IT equipment, and unimportant line connections inside automobiles. These applications do not require high protection levels and have low working environment requirements.

Functional features

Functional features

Sealing performance: Sealed connectors use special sealing materials, sealing rings or structures to prevent external substances such as water, dust and chemicals from entering the interior. This ensures reliable protection against corrosion and short circuits. Non-sealed connectors have a simpler structure and do not use sealing rings or other sealing devices, so their protective performance is low.

Protection level: Sealed connectors are waterproof, can work underwater or in humid environments, and meet specific waterproof standards, such as IP67 or IP68. Unsealed connectors have a lower level of protection and are not suitable for use in harsh environments, such as outdoors, humid or corrosive environments.

Special design: Sealed connectors usually have special connection and locking mechanisms to ensure a strong and reliable connection, so they cost more. They may contain additional sealing components such as O-rings or sealing threads. Unsealed connectors do not require these additional components and are relatively inexpensive to manufacture.

Dustproof performance: Sealed connectors effectively prevent the entry of tiny particles, dust and other impurities, preventing contamination and electrical problems at contact points. The open connector head of a non-sealed connector helps ventilation and heat dissipation and reduces efficiency reduction caused by temperature rise, so the dustproof performance is lower.

How to maintain

How to maintain?

Whether it is a sealed or unsealed connector, regular maintenance is required to ensure proper operation and extend service life.

Appearance inspection: Regularly inspect the appearance to ensure there is no damage. Sealed connectors require inspection of the condition of the plastic housing, plating, and seals, and unsealed connectors require inspection of the pins, sockets, and housing. If damage is found, repair or replace it in time.

Cleaning: Clean the connector surface regularly to remove dust, dirt, grease, etc. Use a clean cloth or cotton swab; do not use solvent-based cleaners.

Testing: Sealed connectors require regular testing of their sealing performance to ensure the protection is effective. Non-sealed connectors need to test the contact status of the connection to ensure a good connection. Testing tools such as pressure testers or multimeters can be used for these tests.

In addition, please pay attention to the following points when using:

• Proper installation: Follow the correct steps to install the connector to ensure proper operation.
• Avoid overloading: Connectors cannot withstand excessive current or voltage to avoid damage.
• Periodic inspection: Check the connector regularly to ensure normal operation.

In summary, sealed and unsealed connectors have different uses in automotive and industrial applications, with sealed connectors providing environmental protection while unsealed connectors are used in less demanding conditions. Connector selection depends on specific application requirements.

Connector Industry Forecast to 2024

Pandemic-era supply chain disruptions and demand imbalances a year ago continue to weigh on the connector industry. These factors have improved as we enter 2024, but new technology trends and other uncertainties are changing the landscape. Here’s what to expect in the coming months.

Entering the new year, the connector industry is facing a series of challenges and opportunities. Global conflicts are putting pressure on supply chains when it comes to accessing materials and opening shipping lanes.

Labor shortages continue to impact manufacturing, especially in North America and Europe. However, demand is strong in many markets. The implementation of 5G and sustainable energy infrastructure is creating new opportunities.

Investing in chip manufacturing will soon bring new facilities into operation. The continuous development of new technologies is driving innovation in the interconnection field, and in turn, these new connector products are also achieving greater achievements in electronic design.

Connector Industry Forecast to 2024

Impact in 2024 five major trends in connectors

SWaP

It is the top priority for connector design and specification in every industry. Product design has achieved astonishing size reductions and performance leaps in high-speed interconnects, thanks to the contributions of component designers. The widespread use of portable, connected devices is transforming every product category and, over time, the way we live our lives.

In addition to small devices, large products such as cars, spacecraft and aircraft also benefit from this miniaturization trend. Smaller, lighter components not only help reduce payload but also open up the possibility of travelling farther and faster.

Customization

While the long development time and high cost of custom components prompted the emergence of a thousand standardized, superior multi-function COTS components, new processes such as digital modeling, 3D printing and rapid prototyping allow designers to quickly and Get perfect, uniquely designed parts without too much of an expensive burden.

Advanced packaging enables designers to push the limits of Moore’s Law, replacing traditional integrated circuit designs with new strategies that integrate chips, and electrical and mechanical components into a single packaged device. Multi-chip modules, system-in-package (SIP), 3D IC, and other creative packaging designs are enabling huge performance improvements.

New material

Materials science is addressing market-specific needs and industry-wide challenges, including weight reduction, reinforcement and durability; biocompatibility and sterilization requirements, and the need for products that are safer for the environment and human health.

Artificial intelligence AI

AI technology is making a splash in 2023 with the arrival of generative AI models. In 2024, the technology will be applied to component design to optimize performance, increase efficiency, test systems and designs, and explore new formats.

At the same time, the extreme demand for high-speed performance required to facilitate these functions will put greater pressure on the connector industry to create new and more powerful products.

Forecasts for 2024 mixed

Forecasting is always difficult, especially in times of financial and geopolitical uncertainty. Predicting future business conditions in this environment is nearly impossible. The economic market remains unstable after the epidemic.The GDP growth rate of all economies around the world is slowing down, and the problem of labor shortage still exists.

Although shipping and trucking Increased freight capacity has led to significant improvements in global supply chain issues, but we still face some obstacles posed by labor shortages and global conflicts. Even so, the global economy appears to be performing better in 2023 than most economists expected, setting the stage for strong economic development in 2024.

Bishop & Associates expects positive connector growth in 2024. Growth in low to mid-single digits is the historical norm for the connector industry, with demand experiencing a historic rebound after a year of decline.

Report investigation

Asian companies are reporting a very pessimistic outlook. Global connector sales will remain essentially flat in 2023, although a surge in activity toward the end of the year could signal an improvement in 2024. Bookings for November 2023 are up 8.5%, November’s book-to-bill ratio is 1.00, YTD is 0.98, and the industry backlog is 13.4 weeks.

The market-leading this growth was transportation, with year-on-year growth of 17.2%; automotive followed with 14.6%, and industrial with 8.5%. Orders increased year-on-year in four of the six regions, with China experiencing the fastest growth. Even so, all regions continue to post negative results year-to-date.

Bishop’s Connector Industry Forecast 2023-2028 report provides an in-depth look at the connector industry’s performance going back throughout the pandemic recovery period, including a full report in 2022, a preliminary assessment in 2023, and a 2024 through 2028 detailed forecast. You can learn a lot about the electronics industry by looking at connector sales by market, region, and product type.

Observation Display

Europe ranks fourth among the six regions for percentage growth in 2022, but ranks first in 2023, with projected growth of 2.5%.

Sales of electronic connectors vary by market segment. The telecom/datacom market will register the largest percentage growth at 9.4% in 2022, driven by increased internet activity and the continued push for 5G. In 2023, the telecom/datacom market will again show the largest growth, growing by 0.8%, although nowhere near the growth seen in 2022.

In 2023, the telecom data communications market will be followed by the military aerospace market with a growth of 0.6%. The military/aerospace market hasn’t moved beyond key markets like automotive and industrial since 2019, but unfortunately, global turmoil has put military/aerospace spending in the spotlight.

In 2013, North America and Europe accounted for 42.7% of total sales, while the Asian market (Japan, China and Asia Pacific) accounted for 51.7% of global connector sales.

In fiscal 2023, North America and Europe are expected to account for 45% of global connector sales, an increase of 2.3 percentage points from 2013, while the Asian market is expected to account for 50.1%, a decrease of 1.6 percentage points.

Connector Outlook to 2024

The new year is full of endless possibilities, and what the future holds is still to be revealed. What we can be sure of, however, is that electronics will continue to play a pivotal role in driving the world forward. As an emerging force, the importance of interconnection technology is self-evident.

As technology continues to advance, interconnection will provide key support for various innovative applications and become an indispensable cornerstone of the digital age. Whether it is the popularization of smart devices, the expansion of the Internet of Things, or the advancement of artificial intelligence, interconnection technology will play a vital role.

We have reason to believe that in the new year, electronic products and interconnection technologies will continue to go hand in hand and jointly write a wonderful chapter in the future.

Revealing connector insertion and extraction force: influencing factors and practical tips

The connector serves as a crucial component for transmitting signals and electrical energy, finding extensive applications in electronic devices, household appliances, automobiles, communication systems, and various other domains.

The insertion and withdrawal force stand as pivotal metrics for assessing connector performance. Consequently, it prompts the inquiry: What elements influence the plugging and unplugging forces of the connector?

The connector serves as a crucial component for transmitting signals and electrical energy, finding extensive applications in electronic devices, household appliances, automobiles, communication systems, and various other domains. The insertion and withdrawal force stand as pivotal metrics for assessing connector performance. Consequently, it prompts the inquiry: What elements influence the plugging and unplugging forces of the connector?

Factors affecting connector insertion and extraction force

Material selection

The composition of a connector material plays a substantial role in determining its mating and unmating forces. In broad terms, metal materials tend to exhibit higher hardness and strength, resulting in increased plug-in and pull-out forces for the connector.

Conversely, non-metallic materials like plastics typically have lower hardness, leading to comparatively smaller plug-in and pull-out forces. When choosing materials, a careful balance must be struck, considering specific application scenarios and performance criteria.

Design structure

The structural design of the connector also affects the mating and uniting force. For example, a connector with a threaded connection needs to overcome the friction of the threads when disassembling;

While a snap-on connector needs to overcome the friction between the slots. Structural parameters should be fully considered during design to achieve appropriate insertion and extraction forces.

Contact resistance

During the plugging and unplugging process of the connector, the contact resistance will change, thus affecting the plugging and unplugging force. The greater the contact resistance, the greater the insertion and extraction force.

Therefore, when designing and using connectors, contact resistance should be reduced as much as possible to improve plugging and unplugging performance.

Environmental factors

Environmental factors, such as temperature, humidity, dust, etc., can also affect the plugging and unplugging force of the connector. High temperature will reduce the elasticity of the connector and reduce the plug-in and pull-out force;

In an environment with high humidity, a conductive film may form on the surface of the connector, increasing the contact resistance, and thereby affecting the plug-in and pull-out force.

Number of plugging and unplugging

The number of times a connector is plugged and unplugged has a significant impact on its plugging and unplugging force. As the number of plugs and pulls increases, factors such as material fatigue and contact wear of the connector will cause the plug and pull force to gradually decrease.

Therefore, in practical applications, the number of plugging and unplugging times of the connector should be controlled to extend its service life.

Practical tips for improving connector insertion and extraction force

Choose high-quality materials

Choosing materials with high strength and low friction coefficient can improve the plug-in and pull-out force of the connector. In addition, material surface treatment, such as gold plating, spraying, etc., can be used to reduce contact resistance and improve plugging and unplugging performance.

Optimize design structure

In connector design, structural parameters, such as contact area, thread specifications, etc., should be fully considered to achieve appropriate insertion and extraction force. At the same time, automatic fastening, spring-assisted and other structures can be used to reduce the insertion and extraction force and improve the convenience of use.

Control contact resistance

The contact resistance of the connector directly affects the insertion and extraction force. Therefore, during the design and production process, contact resistance should be strictly controlled to ensure its stability during use.

Pay attention to environmental protection

Connectors should be protected from environmental factors during use. For example, in high-temperature and humid environments, auxiliary equipment such as radiators and moisture-proof covers can be used to reduce the impact of the environment on the connector.

Connector plug-in and pull-out force

Reasonably control the number of plugging and unplugging

To extend the service life of the connector, the number of plugging and unplugging should be reasonably controlled. In practical applications, modular design can be used to reduce the frequency of connector use, thereby reducing the impact of plugging and unplugging forces on the connector.

The connector plug-in and pull-out force are affected by many factors. By selecting high-quality materials, optimizing the design structure, controlling contact resistance, paying attention to environmental protection and rationally controlling the number of plug-in and pull-out times, the plug-in and pull-out performance of the connector can be effectively improved.

 

A brief analysis of the differences between terminal blocks, connectors and connectors

The usage range, functions and application fields of terminal blocks, connectors and connectors are as follows:

Conceptual differences

Terminal block: an electrical accessory that facilitates wire connection. Metal conductors are encapsulated in insulating plastic parts, and there are holes for inserting wires at both ends. If two wires need to be connected or disconnected, terminal blocks can be used to easily connect them without soldering or wrapping.

Connector: Also known as the plug-in connector, it is a component commonly used by electronic engineering technicians. Also known as plugs and sockets, they connect two active devices to transmit current or signals.

Connector: Positioning connector, consisting of a plug-in and a connector, which can be completely separated. Similar to a switch, circuit switching is achieved by changing the contact state, but the connector only has two states: insertion and removal, and cannot be switched on the body.

Scope difference

Scope difference

Connectors and connectors: Connectors are the connection between wires and wires, and connectors are the connection between wires and boards and boxes. In daily life, people often regard the two as the same concept.

Terminals and connectors: Connector is a general term, and terminals are one type of connector category. Common connectors include rubber shells and terminals. The rubber shell is mainly made of plastic and plays a protective role; the terminals are made of metal and play a conductive role.

Relationship between the three: In the field of electrician and electrical, connector and connector (or plug-in connector) refer to the same concept. In layman’s terms, they are devices that can be quickly connected by plugging and unplugging by hand. Terminal blocks require tools (such as screwdrivers, and cold press pliers) to assist in connection, and are generally used for power input and output.

Application differences

Application differences

Connectors are widely used in various industries. Specific classifications include rectangular connectors, circular connectors, ladder connectors, etc. Terminal blocks are used in the electronic and electrical fields, such as internal and external connections of PCB circuit boards, printed boards and power distribution cabinets.

The scope of use of terminal blocks is expanding day by day, and there are many types. Common ones include PCB board terminals, hardware terminals, nut terminals, spring terminals, etc. In the power industry, there are special terminal strips and terminal boxes for various types of terminal blocks, such as single-layer, double-layer, current, voltage, ordinary, breakable, etc.

terminal blocks

In short, connectors, terminal blocks, and connectors belong to the same concept, but they are used in different actual scenarios and have their own characteristics and advantages.

Detailed explanation of future connector technology development trends

For consumers, the connector product may be unfamiliar, but it is the most commonly used product by electronic engineers. Connectors are an indispensable component in most electronic products.

They are responsible for transmitting current, voltage or optical signals. They have a wide range of applications and are used in aerospace, automotive, industrial, 3C, medical and other industries.

According to relevant statistics, the global connector market size was US$53.5 billion in 2016. Driven by 5G data communications, automobiles, industry and other industries, the global connector market demand maintains a growth trend. The global connector market size will reach US$60 billion in 2020.

As China has developed into the world’s largest connector market, in recent years, the major industries driving the growth of connectors are 5G communications, electric vehicles and Industry 4.0. This is a rare market opportunity for connector companies.

the global connector market

Traditional connectors need to achieve three major properties, namely mechanical performance, electrical performance and environmental performance. The so-called mechanical performance refers to the performance guarantee of the connector when inserted and pulled out;

The electrical performance includes the requirements of contact resistance, insulation resistance and electrical strength;

The environmental performance requires the connector to have basic temperature resistance, moisture resistance, vibration resistance and Impacts, etc. Emerging markets also need to maintain these basic requirements.

In addition to the above basic requirements, new application markets also have new requirements for connectors, that is, new connectors are smaller, more reliable, stronger wireless performance and have a certain degree of intelligence. This is a new demand in the market.

For enterprises, only when connectors meet such requirements can they seize new market opportunities. The editor believes that generally speaking, the development trends of connector technology in the next few years are as follows:

Six major development trends of connectors

High-frequency and high-speed connector technology

In many 5G communication applications, connectors carry the important task of converting optical signals and electrical signals. With the advent of the 5G Internet of Everything era, 5G’s high data and high transmission requirements are destined to require connector performance upgrades, and high-frequency and high-speed Features become the new requirement.

Connector technology for wireless transmission

In the era of the Internet of Things, wireless technology will also be ubiquitous. In addition to realizing contact connection methods as before, connectors will also ensure wireless transmission connections in many occasions such as industry and automobiles in the future. After all, double protection is the safest.

Smaller and more convenient connector technology

Previous connectors were used for numerous contacts, and they were filled in many expansion card slots. Of course, in the 5G era, there may be dozens of connectors in one optical fiber device, which requires smaller connectors to achieve higher-performance connections.

Connector technology with higher accuracy and lower cost

Since automobiles have very high safety requirements, automobile connectors are already a very large market. With the development of electric vehicles, connectors will require higher precision and cost, and they will be more popular than previous connectors.

More intelligent connector technology

With the advent of the AI era, connectors may not only implement simple transmission functions. In the future, in switching power supplies, in addition to ensuring the data of electrical signals, connectors may be able to perform simple intelligent judgment and protection, output correct data while avoiding power supply failures. Damage, of course this requires the support of IC technology.

Automated production technology of connectors

In traditional connector design and production, manual work accounts for the main part. With the development of industrial automation, especially in precision processing of connectors, grinding tools and CAD, these advanced machines will become the main force of the industry.

Automated production technology of connectors

Connectors are very basic electronic devices. Compared with the slow-growing application markets such as computers and mobile devices, new markets will bring new profit growth points to enterprises.

They are 5G communications, automobiles and industrial markets. Today China’s connector market capacity is gradually expanding, maintaining a double-digit growth trend every year, and has huge potential.

5G is another key factor in the explosion of the communications market. Connectors carry the task of data connection between computers and terminals in communications.

In data communications, wired and wireless communications coexist. This is why the demand for wireless connectors mentioned above will Largely increasing, connectors will continue to grow in communication equipment.

In automotive applications, due to the demand for connectors from automotive entertainment systems and electric systems, in addition to transmitting data between engine management systems, equipment, etc., connectors are also needed between in-vehicle entertainment systems, electronic equipment, etc.

Industrial connectors require stronger reliability and performance. With the construction of the Industrial Internet, stronger connectors are needed between strong industrial equipment and networks, and they have new requirements for connector performance.

the market advances

If enterprises want to seize these opportunities, they must overcome the six major technical problems listed above. Connectors do not necessarily have to have these technologies at the same time. For different markets, their requirements may be different. As the market advances, these requirements will be gradually implemented.

 

Comparative analysis of domestic connectors and imported connectors

With the rapid development of science and technology, connectors are increasingly used in various industries. As an important part of electronic equipment, connectors not only ensure equipment performance, stability and reliability but also play a vital role in the development of my country’s industrial chain.

This article will compare and analyze the advantages and disadvantages of domestic connectors and foreign connectors to help everyone better understand the characteristics and application scenarios of these two connectors.

Advantages of domestic connectors

Price advantage: Compared with foreign connectors, domestic connectors have obvious advantages in production costs, which can reduce the overall procurement cost.

Customized services: Domestic connector manufacturers can provide customized services according to customer needs to meet the needs of special application scenarios.

Policy support: Our government has given strong support to the development of the connector industry, which is conducive to the technological innovation and market expansion of domestic connector companies.

Geographical advantage: Domestic connector companies are close to the domestic market and can respond to customer needs faster and provide timely after-sales service.

Advantages of domestic connectors

Disadvantages of domestic connectors

Technical level: Compared with imported connector companies, there is still a certain gap in the technical level of domestic connectors, especially in the field of high-end connectors.

Product stability: Some domestic connectors may experience performance degradation and higher failure rates during long-term use.

Brand influence: Compared with well-known foreign connector brands, the brand influence of domestic connectors is weak and the market competitive advantage is not obvious.

Disadvantages of domestic connectors

Advantages of imported connectors

Technical advantages: Imported connector companies have a high level of technological R&D and innovation, with stable product performance and reliable quality.

Brand advantage: Well-known foreign connector brands have high market visibility and good reputation, and have high customer trust.

Global services: Imported connector companies have production bases and sales networks around the world and can provide customers with a full range of services.

Advantages of imported connectors

Disadvantages of imported connectors

Price disadvantage: Due to higher R&D and production costs, the price of imported connectors is higher than that of domestic connectors.

Difficulties in customization: Imported connector companies have large production scales, and it is relatively difficult to adjust production lines and provide customized services.

Policy disadvantages: Imported connector companies face policy risks in domestic and foreign markets, which may affect their market development in China.

Disadvantages of imported connectors

To sum up, domestic connectors and imported connectors each have advantages and disadvantages. In actual applications, appropriate connectors can be selected based on comprehensive considerations such as demand, budget, product performance and other factors.

With the continuous development and technological innovation of my country’s connector industry, the advantages of domestic connectors in terms of technical level, product quality and market competitiveness will gradually emerge, and they are expected to replace imported connectors to a certain extent and meet the domestic market demand.

What new changes does the development of automotive intelligence bring to connectors?

Driven by the market and policies, automobile intelligence is developing rapidly. As one of the largest markets for connectors, what new changes will the automotive market, whose intelligence process continues to accelerate, bring to the connector industry?

The first half of the automobile “electrification” revolution is being staged fiercely, and the second half of the “intelligent” revolution has also quietly sounded.

In recent years, the new energy vehicle market has developed strongly, and car companies have begun to “roll” towards intelligent network development. In early August, Musk announced on social platforms that Tesla is expected to achieve full autonomous driving by the end of the year, that is, L4 and L5 level autonomous driving. Immediately afterwards, Toyota also announced that it would establish a joint venture with Chinese emerging company Pony AI to enter the field of self-driving taxis, with the goal of realizing the practical use of self-driving taxis as early as 2024.

As my country’s automobile intelligence enters a new stage of development, favourable policies have also been introduced. Recently, the Ministry of Industry and Information Technology and the National Standardization Committee jointly revised and issued the “Guidelines for the Construction of the National Internet of Vehicles Industry Standard System (Intelligent Connected Vehicles) (2023 Edition)” (hereinafter referred to as the “Guidelines”), aiming to combine the development status of my country’s intelligent networked automobiles. Set up a technical logic framework of “two horizontal and three vertical” and build an intelligent and connected vehicle standard system including the basis, technology, products, test standards, etc. of intelligent and connected vehicles.

As the “blood vessel” of the automobile assembly system, the connector plays an important role in connection and transmission. A traditional fuel vehicle requires hundreds to thousands of connectors; electric vehicles require even more connectors due to the addition of battery devices. As one of the important markets in the connector industry, driven by new standards, the rapidly developing smart car market will usher in a new round of changes, which will undoubtedly bring new trends to connector companies.

Current status of automotive intelligence development

L2 is popularized, L2+ still needs to leapfrog

The development of automobile intelligence is mainly divided into two aspects: “autonomous driving” and “Internet of Vehicles”. The development of autonomous driving can be divided into six stages: L0, L1, L2, L3, L4 and L5, of which L5 is truly fully autonomous. driving, and the Internet of Vehicles is mainly the development of “Ethernet”. The development of autonomous driving and the Internet of Vehicles are closely related and closely connected. Whether they can advance from L2 to L3, L4 or even L5 will be a watershed in the development of automobile intelligence.

At present, my country’s automobile intelligence is still at the stage of popularizing the application of L2-assisted driving and piloting and promoting L3 and L4-level autonomous driving. According to data from the Gaogong Intelligent Automobile Research Institute, the number of domestic new cars equipped with forward ADAS (Advanced Driving Assistance System) in 2021 will be 8.0789 million, a year-on-year increase of 29.51% – of which the number of new cars equipped with L2 ADAS will be 395.62 million vehicles, an increase of 77.65% year-on-year. At the same time, the annual insurance volume of new L2+ ADAS vehicles has also shown a rapid increase.

New changes in connectors

New changes in connectors

Thinness, thinness and reliability are key

Perception, decision-making, and control are the three development aspects that are the core of the intelligent operation of automobiles. The path to achieving this is to detect data by the sensor system, then use algorithm technology to make decisions on the sensed information, and finally issue instructions through the control system to complete the control of the entire vehicle. control actions.

In the process from perception to control, ultrasonic radar, millimetre wave radar, cameras, GPS and other devices need to be connected, which requires relying on RF connectors and Ethernet connectors in high-speed connectors. RF connectors mainly include Fakra connectors, Mini-Fakra connectors HSD connectors, etc., which are mainly used for the transmission of RF signals, GPS, vehicle Internet access, etc.; Ethernet connectors mainly help the electronic control units in the car communicate. transmission.

The stability and reliability of signal transmission have a direct impact on the operation of automobile intelligent systems. It can be seen that with the advancement of automobile intelligence, such as RF coaxial connectors, Mini-Fakra, floating board-to-board, and smart cockpits The development space of automotive signal end connectors such as connectors and SPE connectors is promising in the future.

With the integrated development of automation functions, sensing and decision-making functions, etc., the demand for data transmission will continue to increase, placing new requirements on the transmission frequency of RF connectors and the stability of Ethernet connector transmission. Under the condition that the transmission rate is greatly increased, whether high-speed connectors can have higher reliability and whether they can be immune to electromagnetic influence in an all-electric high-power environment. Also in the development of intelligent automobiles, can connector manufacturers The key is to break through the “stuck” problem and seize the opportunity.

The development of automobile intelligence means that complex intelligent hardware systems must be installed in a limited vehicle space to achieve more stable perception, decision-making, and control effects. This requires that connectors must develop towards thinner, lighter and smaller sizes. High-speed connectors that were originally large in size and had low transmission rates may be withdrawn from the market. This will also be a new round of survival of the fittest.

Just like compared with the Fakra connector, the Mini-Fakra connector has gradually occupied the market with its advantages of high transmission frequency, small size and high integration. As the number of smart car chip applications gradually increases, Ethernet connectors are also expected to replace the new differential connectors in HSD connectors.

Car connector industry chain

New Trend in Connectors: Domestic Alternative Welcome Machines

The development of smart cars has entered the deep water zone. The country has introduced favorable policies such as the integrated development of “car energy, road and cloud”. Domestic car companies have “judged the trend” and are planning to move towards new tracks.

In June, Li Auto officially announced that urban NOA (autonomous navigation-assisted driving) will be open for internal testing in Beijing and Shanghai, and the commuting NOA function will be opened within half a year; Xpeng Motors also announced not long ago that urban NGP (intelligent navigation Assisted driving) function has been officially opened in Beijing. At the same time, Cyrus and Avita also announced plans to launch city-level intelligent assisted driving functions.

the connector industry

The rise of terminal manufacturers indicates the strong momentum of my country’s automobile industry in the second half of the intelligent revolution and indicates that Chinese automobile brands will gradually increase their voice in the second half of the track. On the fast lane of smart car development, if connector companies can quickly deploy and implement industrial and technological changes, they can still create a vast world.

The rise of China’s intelligent automobile manufacturing will surely bring new opportunities for domestic substitution in the connector industry.

 

Automotive connection: domestic alternative acceleration, analysis of panoramic analysis of the industrial structure

Car connectors are widely used in power systems, body systems, information control systems, safety systems, vehicle equipment and other aspects.

With the acceleration of the intelligent trend of automobiles, the amount of vehicle sensors increases, the data transmission requirements (high-speed high-frequency large data volume) increase accordingly, the amount of intelligent connected connectors also increases, and new categories such as high-voltage connectors, high-speed connectors and other new categories The amount in the car is expected to usher in a jump.

Overview of the car connector industry

Overview of the car connector industry

As a key basic component, the connector is used to realize the connection between the wires, cables, printing circuit boards, and electronic components, thereby transmitting signals or electromagnetic energy, and maintaining changes such as distortion and energy loss between the system and the system.

The main function of the car connector is to achieve the connection of various equipment inside the car. For example, the audio equipment or power sensing equipment needs to be connected through the car connector to improve the adaptability between each equipment to ensure the safety and stability of the vehicle sex.

Its types include round connectors, radio frequency connectors, FCP connectors, I/O connectors, etc.

Car connectors have high technical and production technology barriers, which are specifically reflected in mechanical performance, electrical performance, and environmental performance.

Car high-pressure connector

Car high-pressure connector

In traditional cars, the connector is mainly low-pressure.

In the new energy vehicle electrical connection system, the three electronics system is the core incremental component of new energy vehicles. The high-voltage connection system connects the three-electric system like a nerve. Its main function is to ensure that the vehicle’s high-voltage interconnection system, that is, in the internal circuit of Blind or unprepared bridges circulates current.

Car high-frequency high-speed connector

Car high-frequency high-speed connector

Car high-frequency high-speed connectors can be divided into coaxial connectors (including FAKRA and Mini-Fakra, mainly transmit analogue signals) and differential connectors (including HSD and Ethernet connectors, connecting twisted cables, mainly transmitting digital signals) Essence

Intelligent car supporting data transmission speed has been increased from 150Mbps to 24Gbps, and the car has developed to integrated development to promote the use of MINIFAKRA and HSD to replace traditional FAKRA connectors.

With the volume of the autonomous driving models of the L3-L5 in the future, the demand for high-voltage and high-speed connectors is expected to increase index.

Car connector industry chain

Car connector industry chain

The upstream industries of the connected industry include metal surface treatment services, metal materials, plastic raw materials, etc. The cost of raw materials will be affected by commodity prices such as copper, tin, nickel and oil.

The competitive landscape of the downstream industry in the connection device is stable and mostly traditional industries, mainly including communication, automobiles, consumer electronics and industrial control.

Most of these industries are industries that have developed mature, with high viscosity in customers, and the market mostly shows a high concentration.

Therefore, the traditional connector market has high barriers, and it is difficult for domestic connectors to compete directly with these industries.

The car connector industry structure

The car connector industry structure

The development of automobile connectors is related to the maturity of the automotive industry.

The connection device industry has a high concentration, with sufficient competition. The traditional large manufacturer of traditional connectors has an absolute advantage, and it still has a trend of continuous improvement.

Since 1980, the market share of the top ten major connector suppliers in the world has increased from 38.0% to 60.8% in 2020. In 2020, Tyko Electronics’s share in the connector market reached 16%, Afino reached 12%, and Mo Shi accounted for 8% of the market share.

The automobile industry in the United States, Europe, Japan and other countries and regions started early. With long-term technology and customers accumulated in high-end high-voltage and high-speed connectors, they are in a competitive advantage.

In the context of the current domestic market demand and the limited production capacity of the international front-line connectors, high-voltage and high-frequency high-speed automobile connector manufacturers are expected to usher in a valuable domestic alternative window period.

The domestic high-voltage connector representative Ryochia started the first generation of high-voltage large-current connectors in 2012. The high-speed connector represents Yihua shares in 2015 and developed high-speed connectors.

The main manufacturers of domestic high-speed and high-voltage connectors include Yihua, Electronics, Limu Electronics, Hexing, Lixing Precision, Aerospace Electric, China Aerospace Optoelectronics, De Run Electronics, Yonggui Electric, etc.

On the whole, foreign manufacturers have strong innovation capabilities, with customer advantages, and occupy market leadership. Domestic manufacturers have the advantages of local supply such as flexible and short delivery cycles.

They are expected to seize opportunities such as policy support, connectors upgrade opportunities to explore new standards in the industry and support of downstream local manufacturers.

In the short term, domestic manufacturers are expected to seize the mid-to-low-end market by purchasing product design and using the Ethernet connector standard to formulate the right to raise the market and seize the opportunity of car network restructuring.

 

Wiring methods and advantages and disadvantages of in-line connectors

Through-hole Connector is a common type of electronic component connector, also known as a socket or plug. They are commonly used to connect electronic components or devices to circuit boards (PCBs). In-line connectors get their name because they plug directly into pre-designed slots or holes without additional soldering.

These connectors are usually made of metal or plastic and have multiple pins or pins, the number and arrangement of which vary depending on the specific application and needs. These connectors are widely used in electronic equipment, computer hardware, communication equipment, automotive electronics, etc., and are popular for their convenient and reliable connection methods. When assembling electronic equipment, in-line connectors can speed up the production process and facilitate the maintenance and replacement of failed components.

Function

Function

In-line connectors play a vital role in electronic equipment and circuits, and their functions and functions mainly include the following aspects:

Circuit connection: used to establish a circuit connection between electronic components, modules or equipment. They allow components on a circuit board (PCB) to be connected with other boards, wires or cables to form a complete electronic system.

Signal transmission: The pins or pins of the connector are connected to realize signal transmission. These signals can be data, audio, video, control signals, etc., allowing efficient communication and exchange of information between different components.

Power connection: It can be used to connect the power cord to pass the power from the power adapter, battery or power module to the circuit in the device. They provide power input for the proper operation of the device.

Modular design: It is helpful to achieve modular design because it allows modules or parts with different functions to be plugged in and pulled out. This design makes the maintenance and upgrading of the equipment more convenient, and at the same time speeds up the production process.

Repair and replacement: Electronic devices using in-line connectors are easier to repair and replace. If an element is damaged or fails, it can be easily pulled out and replaced with a new connector

Equipment assembly: The equipment assembly process is simplified. On the production line, workers can quickly insert connectors into predetermined slots or holes, enabling efficient assembly.

Flexibility: The connector provides a reliable connection between the internal components of the device, allowing designers to have more flexibility in layout and connection, improving the degree of freedom in circuit design.

Wiring method

Wiring method

Wiring an in-line connector is usually a relatively simple process, but the exact steps and methods may vary depending on the connector type and application. Before wiring an in-line connector, you should ensure that you understand the specifications and requirements of the connector you are using, and take appropriate precautions, such as de-energizing, etc., to ensure safe operation. The following are the general wiring steps:

Preparation

Make sure you have the correct type and specification of the in-line connector and the electronic component or device you need to connect it to.

Check that the pins and sockets of the connector match the design of the board.

Confirm the orientation of the connector, usually, there will be a mark or score on the connector to indicate the correct insertion direction.

Confirm pins and functions:

Consult your connector’s data sheet or spec sheet for the function and purpose of each pin.

Confirm the pins and corresponding functions of the electronic components you need to connect.

Plug-in connector

Insert the in-line connector into the corresponding slot or hole on the circuit board in the correct orientation.

Be careful not to insert the connector with excessive force as this could damage the pins or the board.

Connection pin

Make sure that the pins on the connector correspond correctly to the pins on the board.

Using a soldering tool and the appropriate solder, solder the pins of the connector to the pins on the board.

Pay attention to proper soldering to ensure that the solder joints are solid and reliable.

Test connection

After completing the soldering, you can check that the connection was successful using an appropriate test device or method.

A multimeter or test instrument can be used to check continuity and correctness between pins.

Please note that if you have no experience or are not familiar with the wiring and welding operations of electronic equipment, it is best to ask professional electronic technicians to do the wiring work to avoid possible damage and failure. Improper wiring and soldering can cause equipment damage, malfunction, and possibly even safety issues.

Advantages and disadvantages

Advantages and disadvantages

In-line connectors have many advantages and some disadvantages in electronic equipment and circuits

The main advantage

Ease of use: In-line connectors can be inserted and removed quickly and easily, making assembly, maintenance and replacement of equipment easier.

Reliability: When properly connected and soldered, in-line connectors provide a reliable electrical connection for stable signal and power transmission.

Modular design: In-line connectors support modular design, allowing modules with different functions to be plugged in and pulled out, making the design of the device more flexible and expandable.

High-density connection: DIP connector allows high-density connection in a limited space, suitable for scenarios requiring a large number of connections.

Rapid production: On the production line, in-line connectors can speed up the equipment assembly process and improve production efficiency.

Repairability: The in-line connector makes the repair of the device easier, and damaged parts can be replaced without replacing the entire device.

Wide application: In-line connectors are widely used in electronic equipment, computer hardware, communication equipment, automotive electronics and other fields.

Main disadvantage

Main disadvantage

Space constraints: Some application environments may have space constraints that prevent the use of large in-line connectors and require a smaller connection solution.

Pin count limitations: Some in-line connectors may have limited pin counts and are not suitable for complex circuit connection needs.

Soldering skill requirements: The soldering of connectors requires certain skills and experience, and improper soldering may lead to unreliable connections.

Limitation of mating times: The pins and slots of the in-line connector may wear out after repeated mating and removal, affecting the connection quality.

PCB support is required: In-line connectors require proper PCB design and soldering, and are not suitable for connection requirements of some special materials or non-standard PCBs.

In simple terms, the advantages of in-line connectors are convenience, reliability, flexibility and speed, but in some specific application scenarios and design requirements, it may be necessary to consider its space and pin number limitations, as well as appropriate soldering techniques. Proper selection and use of in-line connectors can maximize their advantages and meet the connection needs of specific equipment.

PCB support is required

Zhejiang Lianhe Electronics Co., Ltd. is a company specializing in the production of connectors. Welcome new and old customers to come and buy.

Introduction to the general design of connectors

Connectors are also called connectors. Also known as joints and sockets in China, they generally refer to electrical connectors. That is a device that connects two active devices, transmitting current or signals.

The male end and the female end can transmit information or current after contact, also known as a connector. This article introduces some conventional designs of connectors.

The function of the barb design of the connector terminal

The barb design of the connector terminal can effectively improve the connection stability and reliability of the connector. The barbs can increase the friction between the terminal and the plug, making them lock together more tightly, preventing loosening or falling off when plugging and unplugging.

In addition, the barb can also cooperate with the pin on the connector to make the connection stronger and prevent the pin from accidentally jumping out, thereby preventing wrong insertion and shaking.

Common anti-misplacement and fool-proof designs for connectors are as follows:

Physical shape: The shape, colour, shape and other physical characteristics of the connectors are different. Some connectors are also equipped with rib grooves or dense patterns in the flat socket for correct assembly.

Appearance marking: The connector is usually marked with information such as polarity, lead number or code on a prominent position on the appearance so that it can be inserted or fixed correctly.

Mating design: Some connectors are designed to be used as a pair, that is, different connectors can only be inserted or fixed if they are matched correctly.

Internal guide: The internal design of the connector can use guide shapes or protrusions and other structures, so that only certain plugs with corresponding shapes can be inserted in certain positions, thereby preventing misalignment.

Security feature: A bite or bayonet area is processed in the plug or socket. When the plug is inserted into this area, it can ensure that the plug is in the correct position, thereby preventing the plug from being misplaced or reversed.

These designs can reduce the error rate of the connector and improve the reliability and stability of the equipment.

The above is an introduction to the conventional design of connectors. Zhejiang Lianhe Electronics Co., Ltd. is a professional manufacturer of connectors. Welcome new customers to come to buy.

How to choose a waterproof plug for a car wiring harness connector?

In the car, the whole vehicle can be divided into dry area and wet area. There are differences between dry and wet areas. As the neurons of the car, the waterproof performance of the wiring harness in different areas also has different protection level requirements, which can ensure the normal operation of the entire circuit. Wiring harnesses with different levels of protection can ensure that the performance of the vehicle is in the best state during operation.

After the selection of the waterproof plug after the connector is selected, there are also several important parameters to refer to, such as: the inner and outer diameter of the waterproof plug, the outer diameter of the blind plug, the inner diameter of the connector hole, and the outer diameter of the wire insulation. Whether the relationship between these data matches well determines the stability of the waterproof performance of the waterproof connector in the car under various working conditions.

How to select the sealing plugs?

The following is some introduction to the selection of sealing plugs.

1.Definition of the wet area in the middle area of automotive wiring harness

Dry area: The wiring harness installed in the cab, crew room, luggage compartment, etc., does not need to do special waterproof protection treatment area.

Wet area: The area where the wiring harness requires special waterproofing, except the dry area.

 

2.Definition of sealed wire and connector lumen in wiring harness

It is used to isolate the connecting part of the connector and the outer wall of the wire from the external environment. Sealed wire is also called waterproof peg or waterproof plug, which plays a role of protection and sealing. It is usually a soft rubber piece, which is used to plug the socket of the connector without the wire inserted, and the sealing function is the blind plug; generally, there are two states: soft rubber and hard plastic rod. In special cases, the connector itself has a waterproof rubber pad.

The principle of waterproof plug selection

Under normal circumstances, when the waterproof connector is in the factory, the waterproof level of the plug has been determined, and the required sealing plug is also developed accordingly. If the wiring harness factory faces a relatively single customer and the product type is relatively single, then the selection, procurement, storage and use process of the waterproof plugging material is also relatively simple and convenient. However, as the wiring harness factory faces more diversified customers and the product types are more complicated, the selection, procurement, storage, and use of waterproof plugging materials are very complicated tasks for the procurement and management departments of the wiring harness enterprise. In order to simplify the process, corresponding integration can be carried out according to the following rules, reducing the types of materials and reducing the pressure on procurement and storage.

The waterproof performance is reflected by relying on soft rubber parts to fill the wire insulation layer with the inner hole of the connector, so as to isolate the inner cavity of the connector from the outside world. Plug the hole where the connector does not enter the wire with a blind plug to prevent liquid from entering. The size of the drain bolt, wire and connector should be closely matched.Connector hole inner diameter D1, wire insulation outer diameter D2, sealing plug inner diameter D3, sealing plug/blind plug outer diameter D4, as shown in Figure 1 below.

The relationship between the four kinds of outer diameters is as follows:

D1<D4, D3<D2

Considering the tolerances in the processing of connectors and sealing plugs, the relationship between the dimensions of the four outer diameters is:
D4-D1≥0.3mm, D2-D3≥0.3mm

Special attention should be paid to these dimensional relationships when selecting waterproof plugs.

Specifications for the assembly of waterproof bolts and blind bolts

The actual assembly of waterproof plugs and blind plugs is closely related to the waterproof performance of the connectors, and is a key factor to ensure the waterproof performance of waterproof connectors. Unless otherwise specified, waterproof plugs and blind plugs are not allowed to leak above the hole plane of the connector. Special connectors are implemented according to special requirements. In order to reduce the friction between the waterproof plug, blind plug and the outer wall of the connector, some silicone oil can be properly applied to increase the lubricity during implantation, but it is strictly forbidden to use machine oil instead.

When the waterproof plug is threaded on the wire, the leakage size of the wire insulation is also a critical size. Under normal circumstances, the wire insulation should leak outside the end face of the waterproof plug, but not more than 1 mm, as shown in Figure 3 below.

When the wire is sealed or crimped through the sleeve, avoid the sealing plug being pierced. After the waterproof plug is riveted through the sleeve,the wire conductor and the wire insulation layer should be visible in the connection area B. See Figure 4 below.

Waterproof performance verification

For the waterproof performance of waterproof connectors, different Oems have different requirements for the distribution of connectors. For example: some vehicle manufacturers require that the waterproof capacity of the connector in the wet area is required to reach IPX7, that is, it is required to prevent the effect of short time immersion, and the amount of water into the shell will not reach harmful levels after entering the water that reaches the pressure.The tested connectors are immersed in water according to the installation state specified by the manufacturer:

  1. When the height of the connector is less than 850 mm, the lowest point of the connector should be 1000 mm below the water surface.
  1. When the height of the connector is equal to or greater than 850 mm, the highest point of the connector should be 150 mm below the water surface.
  1. The duration of the test in water is at least 30 minutes.
  1. Thetemperature difference between the water temperature and the connector is not greater than 5K.
  1. If the waterproof test is carried out on the connector equipped with wires, the length of the wires must be greater than 1 meter to prevent the end of the wire from being immersed in water and the wire sheath from being damaged. There are gaps between the multi-strand copper wires of the wire core, and the insulation skin forms a pipeline. If the end of the wire is immersed in water, water can enter the cavity of the connector along the pipeline formed by the wire insulation layer.

After meeting the above conditions, if no water accumulation occurs, the waterproof performance is judged to be qualified. The verification method of waterproof performance test is shown in Figure 5.

The non-original connectors are matched with waterproof plugs and blind plugs.After selection and matching, it is necessary to pass the waterproof test before it can replace the waterproof plug and blind plug matched by the original connector.Substitutes that have not been verified by waterproofing tests shall not be used in actual manufacturing processes.

Summarize

Combined with the actual processing practice and the above discussion, the following conclusions are drawn. The selection and application of the waterproof plug of the waterproof connector in the wiring harness directly affect the process quality of the product processing. Waterproof bolts/blind bolts, wires, and connectors must be closely matched. In the selection process of waterproof plugs and blind plugs, the corresponding integration can be carried out without violating the relevant quality requirements of matching gap size and crimping, reducing the types of waterproof plugs and blind plugs, and reducing the inventory and storage management of such products pressure.

In addition, this practice can bring the following benefits, such as, avoid the delivery pressure caused by the long procurement cycle of the original waterproof plug and blind plug and the tight delivery time of customers. It can also reduce the pressure caused by unstable order quantity, multiple varieties, multiple batches, and small single order capacity. It can save the cost of human resources, operation management and quality management within the company.

LHE New product recommendation

LHE recently developed a new product, the following is the introduction of the new product

D6301-H02

D6301-H02 is replacement of JST PS-250-2A-15,Secure locking mechanism and Low insertion force。
Stable contacting performance,Misinsertion (reverse insertion) prevention structure for the contact。
Misinsertion prevention structure for the tab (Short type housing),Glow wire compatible products are also available for short type housings performance。

P0022-T

P0022-T is replacement of TE 62308 terminals, Pigtail Splice, Splice Capacity 3, Serrated,3000 – 7000 CMA Wire Size, Brass, AMPLIVAR

A20010

A20010 connector is replacement of JST PNI-H series connector
2.0mm pitch,widely use in board-to-wire connection with secure locking
device that has been designed to high box type, with a mounting height of 19.95mm (including retainer) and 6.65mm in depth.
Low insertion force type contact is adopted and it provides excellent operability.Retainer is available as usage.

Above is the recent development of new products, if you are interested, please feel free to contact our salesman.