Heat resistance of connectors

The use temperature is usually shown in the spec sheet of the connector, so the temperature environment defines the temperature range in which the connector will work properly, usually determined by the elephant use environment of the connector. For example, for general types of connectors, the temperature range is minus tens of degrees to more than one hundred degrees. Different temperature levels determine different usage environments. 1: Metallic materials The most commonly used materials for electrical connectors are metal and plastic. Metal provides the function from the most basic contact conduction to electromagnetic shielding. Its failure mode is mainly elastic fatigue. The macroscopic performance is the slow reduction of positive force under force state, and the microscopic reason is the creep of metal lattice under stress. The metallographic and metallurgical treatment methods of each alloy composition are different, and the temperature resistance exhibited by the factory is different. Stress release is related to stress temperature and time, and the tool used in engineering to express the thermal resistance of materials is the stress release curve. You can measure the residual stress of a material in a stressed state at a certain temperature according to time, so as to get the stress relief curve of the material. Different applications differ in sensitivity to stress relief. In automotive connector applications, where chips are typically used, 70% of the initial stress is still required to be maintained after 3,000 hours of aging at 150 degrees. In other applications, it must be confirmed that at the highest operating temperature, there is still a considerable residual stress over a period of time.

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2: Plastic material For plastics, the parameter used by UL to measure the long-term service temperature of the material is the true thermal index (RTI). The RTI shown on the UL yellow card indicates a 50% reduction in temperature using 100,000 hours of dynamic performance (RTI MECH) or electrical performance (RTI ELEC). This parameter indicates the long-term service temperature of the material and ensures a certain safety margin. So, how do you determine how much RTI is needed? The simple design consideration is that the RTI value must be greater than the temperature rise and ambient temperature. The temperature rise can be obtained by designing the temperature rise curve of the terminal defined by the input. 3: Connection Structure The structure of the connector will affect the concentration or dispersion of heat, and ultimately depends on the maximum internal temperature. For connectors that transfer power, Joule heat due to current is the dominant form of heat. There are three forms of heat transfer: conduction, convection, and radiation. So, does the connector design a thermal structure using these three forms, for example, whether there are metal parts that transfer heat, and whether there are hot pins that can reach the fan or natural wind. For example, European new energy vehicles tend to use some connectors with metal housings because of better cooling effect. Designing the proper thermal structure increases the safety and longevity of the connector. When designing, you can adjust the safety factor according to the structural environment. For example, if there is a thermal structure, a lower safety factor can be used to gain economics. Nowadays, in the field of electronic products, connectors are widely used. Many electronic products are prone to heat in the use environment and working state, so it is also a test for connectors. The requirements for equipment connectors are getting higher and higher, and it has become a key point to be able to withstand long-term high-temperature use.

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