Introduction to the structure of electrical connectors

In addition to meeting general performance requirements, electrical connectors are particularly important in ensuring good contact, reliable operation, and convenient maintenance. Their reliability directly affects the normal operation of aircraft circuits and involves the safety of the entire host.

Therefore, the host circuit has very strict requirements for the quality and reliability of electrical connectors. It is precisely because of the high quality and reliability of electrical connectors that they are widely used in military systems such as aviation, aerospace, and national defense. The commonly used classification methods for electrical connectors include appearance, structure, purpose, etc.

Structure:

An electrical connector consists of a fixed end electrical connector, which is a female contact (referred to as a socket), and a free end electrical connector, which is a male contact (referred to as a plug). The socket is fixed to the electrical components through its square (circular) plate (some also use welding), and the plug is generally connected to the cable. The plug and socket are connected through the connecting nut.

Electrical connectors are composed of three basic units: a shell, an insulator, and a contact body.

Shell:

The electrical connector housing refers to the shell, connecting nut, and tail accessory of the plug and socket. The function of the casing is to protect the internal parts of electrical connectors such as insulators and contact bodies (commonly referred to as pins and sockets) from damage. The positioning keyway above ensures the positioning of the plug and socket. The connecting nut is used for connecting and separating the plug socket. The tail accessory is used to protect the wire and contact body from damage and to fix the cable. The shell also has a certain electromagnetic shielding effect.

The shell is generally made of aluminum alloy processing (machining, cold extrusion, die casting). Steel shells are commonly used for glass sealing and high-temperature electrical connectors.

Insulator:

Install pin insulator and socket insulator. Interface sealing body, sealing wire body, etc. Used to maintain the pin and socket in the set position, and to electrically isolate each contact body and between each contact body and the shell. To improve the environmental resistance of electrical connectors, sealing measures are achieved by adding an insulator and an interface sealing body.

To adapt to the high temperature, low temperature, and flame retardancy of the product, ensuring stable and reliable geometric dimensions of the parts. Insulators are mostly molded using thermosetting plastics. The interface sealing body and sealing wire body are formed by using silicone rubber molding, etc

Contact body:

The contact body includes male and female contacts, sometimes also known as pin and socket, and the connection methods are divided into welding type, crimping type, pressing type, and winding type to achieve circuit connection.

Pin and socket are key components of electrical connectors, which directly affect the reliability of electrical connectors. The pin and socket are mostly made of elastic copper alloy material with good conductivity by machining, and the surface is plated with silver and gold to achieve low contact resistance and corrosion resistance. Jacks generally include slot type jacks, wire spring jacks, crown spring jacks, and punched jacks.

The structural features are: environmental resistance, bayonet type (fast) connection, multiple key positions (anti misinsertion), contact body and wire crimping connection, (single piece for easy fault handling). 360 ° electromagnetic interference shielding capability with environmental protection certificate for shell shielding

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