Rugged Miniaturized Connectors: Advancing Compact, Reliable Solutions for Harsh Environments.
Introduction
Advancements in materials science, innovative design techniques, and manufacturing processes are driving the development of next-generation connectors capable of withstanding harsh environmental conditions. They are designed to meet the increasing need for compact, reliable components in vehicles equipped with electronic systems, sensors, cameras, and communication devices. By enabling more circuits in smaller spaces, rugged miniaturization is shaping the future of component design. This article highlights the features and advantages of Molex's rugged miniaturized connectors.
1. The Emerging Trend of Rugged, Miniaturized Connectors
Connectivity solutions that support demanding requirements for power, reliability, high-speed data, shrinking form factors and rugged performance are critical enablers for next-generation connectors. Interconnect technology involves balancing variables such as signal integrity, power quality, data transfer rate, thermal management, form factor, size, and weight to create connectors that can move more power or data. Here are some of the market drivers placing pressure on the requirements of connector design:
- Faster Data Rates: Growing consumer expectations and the proliferation of AI and IoT applications demand higher data transfer speeds.
- Higher Power Throughput: The rise of EVs, renewable energy systems, and portable devices requires faster and more reliable energy transfer. Higher voltage solutions are crucial for quick EV charging but also require redesigning vehicle and charging infrastructure to address safety and thermal challenges.
- Miniaturization: Designers must deliver compact, feature-dense assemblies that meet expectations for ruggedness and efficiency.
- Contactless Connectivity: Emerging contactless solutions offer freedom from manual mating and de-mating, improving reliability, ruggedness, and cost-efficiency compared to mechanical connectors.
1.1 What are Rugged, Miniaturized Connectors?
Rugged miniaturized connectors are compact interconnect solutions designed to withstand harsh environments, and maintain reliable performance and/or stability for high-vibration applications. Ruggedization goes beyond adding protective layers or increasing the bulk of a connector; it's also a holistic approach that considers the entire lifecycle of a component, from design and material selection to manufacturing and testing. Distinct features of rugged miniaturized connectors are:
- Vibration Resistance: Equipped with strong positive locking mechanisms to prevent accidental uncoupling in high-vibration environments. Metal solder tabs enhance strain relief, improving resistance to mechanical stress.
- Extreme Temperature Tolerance: Operate seamlessly between -40°C to +125°C, suitable for extreme temperature applications. High-temperature thermoplastic housings ensure durability and simplify manufacturing processes, withstanding soldering temperatures up to 255°C.
- Ingress Protection: Offer robust protection against dust, dirt, and moisture, with IP ratings like IP67, IP68/IPX8, and IP69k. They are designed to endure rain, dust, disinfection, and even submersion in water, making them ideal for wearable technology and other applications.
- Flame Retardancy: Capable of performing in environments with high fire hazard potential.
- Chemical Resistance: Built to resist harsh chemicals and stress that could degrade plastic materials or affect connector performance.
Rugged miniaturized connectors are critical for enabling advanced features in compact designs while ensuring reliability and durability under extreme conditions.
1.2 How are they different from other kinds of connectors?
Rugged, miniaturized connectors differ from standard connectors with respect to durability, environmental resistance, compact size, specialized materials, and resistance to electromagnetic interference (EMI). Designed to endure extreme conditions such as high temperatures, vibration, shock, and moisture, rugged connectors are well-suited for environments where standard connectors often fall short. Their compact size enables them to deliver high performance in space-constrained applications, while standard connectors, which are generally larger, may not meet these requirements.
Molex employs advanced materials such as high-temperature thermoplastics, reinforced housings, over-moulding, innovative sealing technologies and secure latching mechanisms to create connectors that excel in rugged applications. Design features such as connector position assurance, independent secondary locks, terminal position assurance, and audible clicks upon mating enhance durability and reliability. Additionally, rugged miniaturized connectors include shielding mechanisms to mitigate EMI, ensuring reliable functionality in environments where standard connectors may fail. These features simplify assembly and reduce operator errors, making rugged connectors ideal for high-performance use cases.
1.3 What are the Challenges of Designing Rugged, Miniaturized Connectors?
One of the significant hurdles in miniaturization is the limitation of traditional materials, which often struggle to perform reliably due to large surface area-to-volume ratios and compositional inconsistencies. Advanced insulating materials such as high-performance polymers (HPPs), polyphthalamide (PPA) and liquid crystal polymer (LCP) are employed to address these challenges. These specially formulated polymers provide the necessary strength and durability while minimizing deformation and anisotropy at small scales. These materials maintain a lightweight profile and high strength-to-weight ratio even at reduced dimensions by incorporating innovative fillers and chemistries within the HPP matrix. The challenges of miniaturization extend beyond mechanical strength. Miniaturized connectors must meet stringent requirements, including flame retardancy, chemical resistance, and high-quality manufacturing standards.
1.4 Miniaturization Techniques
Engineers are employing miniaturization techniques to balance robustness and compactness. Dense pitch layouts, which reduce contact spacing and increase functionality within a smaller footprint, are a prime example. However, these layouts present challenges, such as reduced airflow and higher heat density, necessitating advanced thermal management strategies. Techniques sich as efficient signal routing, shielding, and isolation methods help mitigate these issues, while high-precision manufacturing ensures reliability.
A key innovation in this field is the development of multi-functional terminals (MFTs), which integrate multiple functionalities into a single compact unit, eliminating the need for multiple connectors. Miniaturized PCB connectors are another significant breakthrough. These connectors, with their tiny footprints and fine-pitch contacts, allow for reduced device sizes while enhancing functionality. Advanced contact designs—such as spring-loaded contacts—and high-conductivity materials like gold and palladium are utilized to ensure minimal resistance and signal loss.
2. Automotive Industry Example of Rugged, Miniaturized Connectors
Today's vehicle electronics need to be smaller, lighter, more connected, and faster than ever – all while retaining high levels of ruggedness and reliability. From internal engine vibrations and battery heat to extreme factors like mountain ice, desert sand and rain, transportation applications are the ultimate test of connector reliability. These trends are reshaping not only how vehicles are built but also how we interact with them, setting the stage for transformative changes in transportation technology.
2.1 Understanding Market Trends Driving Miniaturization
Molex is developing more miniature, lighter connectors with high-performance power and signal capabilities that can withstand debris ingress and accommodate limited space. Transformational key trends in the automotive industry are connectivity, autonomous driving, in-vehicle experiences, and electrification are shaping the future of vehicle design. The growing use of electronic components in modern vehicles drives the need for miniaturization. Advanced Driver Assistance Systems (ADAS), infotainment systems, and IoT integration require reliable, compact connectors.
Miniaturized electronics are replacing traditional single-use ECUs with embedded computing modules, transforming vehicles into data centres with communication systems akin to computer networks. Interconnectivity is crucial, especially in electrified vehicles, where zonal architectures combine hardware, software, and firmware to enhance functionality. By grouping functions by location, zonal gateways manage devices locally, reducing cable lengths and simplifying data management. This modular approach enables safer, more autonomous driving while meet the demands of modern transportation systems.
2.2 How Component Features Affect Vehicular Reliability
Today’s vehicles often feature up to 80 Electronic Control Units (ECUs) and more than 100 sensors, powering sophisticated systems such as ADAS, infotainment platforms, and enhanced powertrain controls. However, the performance and reliability of these systems hinge on the quality and design of their interconnections.
Molex connectors address these challenges by offering robust solutions tailored to demanding environments. Their rugged designs ensure reliable performance under high vibration, extreme temperatures, and harsh conditions. Advanced shielding supports high-speed data transfer, while low-resistance contacts improve power efficiency. These connectors are also engineered for long-term durability, with features like moisture and corrosion resistance ensuring reliability throughout a vehicle's lifecycle. By balancing durability, efficiency, and space-saving capabilities, Molex connectors play a crucial role in meeting the evolving demands of modern vehicle electronics.
2.3 Optimizing Space Inside and Outside the Box
Miniaturized connectors allow engineers to maximize space within vehicle compartments, enabling the integration of additional features without increasing size or weight. This demand for compact yet highly functional components has driven the development of micro-miniature board-to-board and wire-to-board connectors and innovative automotive I/O and hybrid connectors for unconventional applications.
In addition to external connectivity, inside-the-box connectors (figure 1), are crucial for internal systems such as ECUs. These connectors facilitate connections between components like circuit boards and modules within enclosed systems. Designed for compactness, high reliability, and precision, inside-the-box connectors ensure signal integrity and minimize interference. Molex’s range of board-to-board connectors meets microminiature, high-speed, high-density, and high-power requirements, making them well-suited for the intricate demands of modern electronic systems.
Figure 1: Outside-the-box and Inside-the-box connectors (Image Source: Molex)
Outside-the-box connectors are built for reliability and designed to meet strict industry standards while withstanding external environmental conditions. These connectors link external sensors, cameras, and lighting systems to the vehicle's main electronic framework and facilitate connections between the car and external devices or networks. Molex provides a range of hybrid, high-density, and sealed connectors that offer exceptional performance in harsh environments, making them ideal for the growing demands of electric vehicles.
3. Scope and Best Fit of Rugged Miniaturization
The potential of compact, durable components is vast, with miniaturization and ruggedization merging to create a new generation of components. These components could lead to advancements in fields like flying tractors, eVTOL aircraft, vertical farms, space exploration, aerospace, defense applications, wearable technologies, and remote weather stations. Few of these applications are discussed below:
- Agricultural applications: These are exposed to rugged conditions such as water, dust, and extreme temperature fluctuations. For example, combine harvesters rely on environmentally sealed connectors in engine controls, harvesting heads, control panels, hydraulic systems, lighting systems, and data collection sensors for protection against large amounts of debris.
- Flying Tractors or agricultural drones, have the potential to transform farming by enabling precision operations such as crop monitoring, spraying, and data collection. These drones rely on small but robust connectors that offer high bandwidth and low signal loss, ensuring reliable performance even in challenging conditions. These connectors can endure vibration, shock, and extreme environmental conditions, including dust, moisture, temperature fluctuations, and exposure to corrosive chemicals.
- Electric Vertical Takeoff and Landing Aircraft (eVTOLs): Miniaturized connectors play a key role by reducing weight, maximizing range, and ensuring critical systems remain operational, even in low-altitude incidents. By improving connector performance and reliability, eVTOL companies can also increase their payload capacity, helping to expand their customer base and enhance the aircraft's market potential.
Join the forum discussion or comment below
4. Featured Products
Molex offers a range of products that fall into the miniatures category, such as board-to-board and wire-to-board products. These connectors, such as 1.5mm and 0.6mm or 0.5mm wide terminals, are widely accepted and available off the shelf. The following are key products in Molex's portfolio, highlighting their specialized features and applications.
Figure 2: DuraClik Connectors (Image Source: Molex) |
Figure 3: Mini50 connectors (Image Source : Molex) |
Figure 4: ConnTAK50 connectors (Image Source: Molex) |
Figure 5: Stac64 connectors (Image Source: Molex) |
Figure 6: stAK50h connectors (Image Source: Molex) |
Figure 7: FFC / FPC Connectors (Image Source: Molex) |
Figure 8: Micro-Lock Plus Connectors (Image Source: Molex) Buy Now |
For more Miniaturized Connectors from Molex Shop Now
About the sponsor
As a leading provider of interconnect solutions, Molex has more than 80 years of experience delivering connectivity at scale. Our commitment to the highest-quality products, unmatched engineering expertise and truly collaborative customer relationships spans industries, from automotive to telecommunications, mobile devices, data center, industrial, medtech and more. For more information, go here.
