Automotive Connectors

Well known for its harsh environment, vehicle applications for electronic systems require connector systems that can be easily and securely attached in the production environment. Once installed, the connectors must withstand temperature ranges from -40 to 85C in the passenger compartment and -40 to 125C or more under the hood. In addition to temperature extremes, connectors must handle vibration levels and a variety of chemicals depending on the mounting location that can include oil, brake fluid, coolant and more. Humidity, thermal shock and salt spray are among the conditions connectors can be subjected to during the 100,000 mile life of the vehicle and during the qualification process. Here are three examples of road-worthy connectors.

Harsh Environment Connector System

Tyco's AMPSEAL 16 connector system targets the commercial vehicle industry and heavy-duty industrial applications. The wire-to-wire and wire-to-device connector system has 1.6 mm pin and socket contacts that are stamped and formed versions of screw-machined MIL-C-39029 contacts. To prevent miss-mating, the housings are keyed and polarized. Interface and wire sealing provide environmental integrity. In addition to passing ASTM B117 for 96 hour salt- spray test and 50 durability cycles, the units meet SAE J1455 requirements.

Surface Mount Connectors

Designed specifically for automotive applications, Tyco Electronics' new generation of surface mount automotive connectors eliminate the need for selective solder operations. CAR SMT connectors incorporate a Coplanar Alignment Rib (CAR) that provides terminal position control without requiring additional fasteners for attachment saving pc board space and reducing installation costs. Supporting vertical or horizontal PCB orientation, the terminal position (coplanar location) is controlled within 0.13 mm and can be applied with lower amounts of solder paste. Handling from 4 to 52 circuits, the units have J-shaped terminal leads that provide a large solder area and are compliant to thermal and mechanical stresses, minimizing solder joint stress.

CMC Connector

Roughly translated, the French acronym CMC stands for Modular Connector for Electronic Control Modules. FCI's CMC connectors range from 32 to 48 and now include a 64-way configuration. Widely accepted for vehicle powertrain applications, the CMC connectors are suitable for engine compartment-mounted control units. Delivered in two parts, housing and cover, the wire-to-board connectors provide high sealing performance and withstand high vibration. Additional features include a front holder with a mate-assist design and terminal position assurance. Clean body GTS terminal technology provides high mat-seal performance without requiring a sticky gel and uses less components than other comparable systems. The pre-loaded beams of the single piece terminals allow a high and stable contact force with a low mating force, while providing high current carrying capability.