Electrical connector specification and test requirement
According to different applications, the connector can be divided into military connectors, aerospace connectors, space connectors, automotive connectors, railway connectors, industrial connectors, etc, and the specification can be divided in to 4 parts (electrical, mechanical, environment and environment protection data).
Electrical specification, it is main feature for connector connection.
- 1. Contact resistance
Reduce the loss signal and energy transmission by control connector contact resistance.
Test method MIL-STD-1344A, 3004.1
Main points for test:
- a. Test current/voltage 100mA/20mV, connector non-loaded
- b. Low current is needed for connector test; contact resistance won’t be influenced by contact thermo-electric effect.
- c. Low voltage is required for connector test; interface insulating film won’t be breakdown or melt.
Specification requirement 50mΩ (initial); 100mΩ (final)
- 2. Withstanding voltage
Ensure connector functions when under the condition of switching-impulse voltage or overload accidently.
Test method MIL-STD-1344A, 3001.1
Main points for test:
- a. Survey point position is between two insulators
- b. Test voltage AC (60Hz; sine wave, valid value=0.707*peak) or DC
- c. No breakdown, leakage current ≤5mA
Specification requirement- withstanding voltage for mobile is 100VAC Min
- 3. Insulation resistance
Avoid weak current happens, which will influence signal and energy transmission (especially high frequency signal).
Test method MIL-STD-1344A, 3003.1
Main points for test:
- a. Survey point position is between two insulators
- b. Test voltage DC 100V, 500V, 1000V, 1500V, it depends on connector functions
- c. Duration 2min
- d. If needed, samples should be cleaned firstly, then test after being toasted
- e. No breakdown or spark
Specification requirement- withstanding voltage for mobile is 100MΩ Min
- 4. Temperature rise
Ensure connector security when load for a long time
Test method EIA-364-70
Main points for test:
- a. Start test temperature when thermal equilibrium is attained under loading current.
- b. Test current/voltage is rated working current/voltage
- 5. Contact capacitance
Avoid interference which is caused by current or signal penetration and warranty capacitance.
Test method EIA-364-30
Main points for test-
- a. Test frequency is 1k Hz or 1M Hz
- b. Survey point position is between two insulators
Specification requirement- contact capacitance is about 3pF Max