Introduction to Vehicle Connectors

Automotive connectors are very widely used connectors. Automotive circuits are inseparable from it, ranging from engine modules to camera modules. Its function is to connect circuits and build a bridge of communication. For such an important part, we need to understand it in more detail.

Ⅰ. The basic structure of vehicle connectors

General automotive connectors are divided into four structural components:

1. Outer plastic

The outer plastic is usually injection molded from low-temperature and high-temperature materials. Low-temperature outer plastic is suitable for Wave Solder process, and high-temperature outer plastic is suitable for SMT process. The main function of the outer plastic is to provide the retaining force of the male and female connectors through the buckle on the outer plastic.

2. Shielding shell

The shielding shell is generally made of zinc alloy, usually formed by die-casting, and the copper surface is galvanized. The role of the shielding shell: shielding the signal to prevent external signals from interfering with the work of vehicle connectors.

3. Inner plastic

The inner plastic is generally a plastic part. Through injection molding, the plastic pellets of the inner plastic must be purchased, and its dielectric constant affects the high-frequency characteristics of the connector. Internal plastic function: contain terminal

4. Terminal

The terminals are generally metal stamping parts, which are formed by stamping, and the general materials are brass and phosphor bronze. Terminal function: the common segment contacts with the female terminal to transmit signals.

For the parts of the automobile connector, we also need to choose a reliable connector supplier.

Ⅱ. Design standards for vehicle connectors

With the rapid development of the automobile industry, various functional parts and various parts of automobiles are constantly developing in the direction of intelligence, refinement and reliability. And recently a new removable connector has emerged, which is more convenient and advanced. This also puts forward higher requirements on the structural design, appearance design and materials of automotive connectors. Automotive connectors must comply with the USCAR-20 standard, which is the performance standard of automotive electrical connector systems. It stipulates that the electrical connector contact surface of automotive connectors must always be reliable during the entire life cycle, including the following factors:

1. The material of the automobile connector contact is stable and reliable;

2. The positive force is stable;

3. The voltage and current of the circuit are stable;

4. The temperature requirements are within the specified range, including the surrounding temperature and its own temperature rise;

5. Better robustness;

6. It must be the same as the connector used in the high-speed and long-distance communication computer, and the automobile connector must be able to work reliably under harsh conditions;

7. Heat resistance: -50~220℃

Ⅲ. The selection factors of vehicle connectors

1. Electrical factors

Current requirements: high current, low current, signal level. It determines the type of terminal/size of contact section/plating (pin and male terminals from 0.32mm to 8.0mm). Steady state, cyclic, transient state.

Wire diameter/insulation layer requirements: voltage drop and/or corrosion resistance. It determines the center distance of the car connector.

2. Location/Environment

Temperature: engine compartment-sealed, ambient temperature> 105 ℃, vibration, fluid compatibility; passenger compartment-unsealed, ambient temperature <85 ℃, mainly due to the size factor is more important sealing: potential high-pressure jet / splash; potential Immersion; Humidity; Fluid type; For equipment car connectors, whether the equipment is sealed.

3. Standard

Standards: customer standards; institutional standards; international standards

Automotive connector performance test requirements: included in system-level specifications; other automakers generally have their own standards (similar to USCAR);

Trend: equipment suppliers are responsible for the performance of the mating connector.

The equipment occupies the board fitting half of the car connector interface, the car connector supplier is required to have a good exchange of information on the matching terminal.

Sunkye Connection Technologies provides a wide product portfolio with a complete interconnect solutions offering. Sunkye connectors and cables assemblies are complementary with Sunkye backshells and conduits.