Page 8 - 2021 Connectivity Components: Everything but the Connectors eBook

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fire, shock, and vibration is essential. Materials may further be tested to meet the space industry’s ASTM E595 standard. Notably, matrix composites exist, which provide similar enhanced durability, hardness, and shock resistance. However, existing ceramic matrix and metal matrix composites are not used in commercially available interconnect components.
• High-grade engineered thermoplastics are designed to replace traditional metal connector shells, enabling substantial weight reduction: 17–40% compared to aluminum shells and 60–70% compared to stainless steel. Thermoplastics have a salt-spray rating up to 2,000+ hours.
A vital protocol to assure metal connector shell integrity is the manufacturing step of impregnation. Impregnation refers to the process of removing air from the pores of leakage paths in a casting and replacing it with polymer resin. The resin is forced into the porosity through vacuum and pressure methods, and then cured to form a pressure-tight part.
Plating
Connector shells are generally plated for the primary purpose of preventing shell material degradation from corrosion. (Conductivity requirements may also be met by plating the shell.) Corrosion, the destruction of a metal surface by chemical reaction, is a process whereby a material degrades to a more stable state, such as an oxide or sulfide. Corrosion is ordinarily accelerated by the effects of humidity/moisture, chemical exposure, a corrosive environment, and extreme temperature ranges. This reaction is commonly triggered by external factors (i.e., exposure to corrosive agents) and can be significantly mitigated by component design.
» Automated shell plating processes are vertically integrated at the connector manufacturer to safeguard quality. (Photo courtesy of Amphenol PCD.)
The type of plating applied is largely dictated by the application and compliance to the requisite commercial or military specifications. Nevertheless, the environmental impact of the specific plating methods and the hazardous substances contained in the material are increasingly becoming considerations for end-users and manufacturers alike. Plating options are self-identified as RoHS-compliant or RoHS non-compliant. This refers to the Restriction of Hazardous Substances legislation, also known as RoHS 3 or EU Directive 2015/863, in electrical and electronic equipment. Many popular plating materials specified for use in military applications are RoHS non-compliant, as they were developed long before hazardous materials and environmental concerns were factors. The majority exhibit exceptional harsh environment properties and, together with an anti-reflection coating, are ideally suited for application on the shell and connector accessories.
» Connector shells’ performance and longevity is dependent on the consistency of the plating; specifically, the thickness of the applied material. (Photo courtesy of Amphenol PCD)
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