Importance of material strength during connector design

As connectors become smaller to allow for faster and safer mating, they also become weaker. This is why material strength must be considered during connector design, and it is critical to analyze which conductive metal or alloy material is best suited for the application. The three most commonly used materials for designing connectors are: brass, phosphor bronze (PhBr), and beryllium copper (BeCu). To better understand which material is appropriate for the scenario, consider using a single connector where, when the connectors are paired, there will be a normal force between the two connector halves that creates electrical contact between them. The flexible strength of a connector material is defined as the amount of stress the material can withstand before it deforms (bends, etc.), while the tensile strength is the total force the material can withstand before it breaks. The strengths and capabilities of these three materials are clearly known in the latest specifications. It is important to note that MPa is megapascals, which stands for units of internal pressure and tensile strength. Brass: 69 MPa - 434 MPa Phosphor Bronze (PhBr): 131 MPa - 552 MPa Beryllium Copper (BeCu): 965 MPa - 1205 MPa Phosphor Bronze (PhBr) is not as conductive as brass, but has a higher tensile strength and the solid fit normal contact forces required for a strong fit. To combine the advantages of both, Beryllium Copper (BeCu) not only offers the higher strength of the three materials, but its electrical conductivity is very close to that of copper, making it ideal for strong, reliable connections. Brass, Phosphor Bronze (PhBr) and Beryllium Copper (BeCu) materials are not the choice when it comes to designing reliable connectors, and it's critical to know which materials will meet the needs of your application as new alloys and conductors continue to make their mark in the world of microelectronics.

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