FAQs & Help - connector

Housing: This is the outer structure that holds the internal parts together and provides mechanical protection. It also ensures proper alignment when connecting.
Contacts: These are the conductive elements that carry electrical signals or power between connected devices. They can be pins, sockets, or pads depending on the connector type.
Insulator: This component separates the contacts and prevents short circuits. It maintains the correct spacing and ensures electrical safety.
Shell/Coupling Mechanism: The shell provides shielding against electromagnetic interference (EMI) and mechanical protection. The coupling mechanism, such as a latch, screw, or clip, ensures the connector stays securely connected.

Some connectors may also include gaskets or seals for environmental protection, strain reliefs to prevent cable damage, and keying features to prevent incorrect mating.

What are crimp, solder, and screw connections, and what are their pros and cons?

Crimp, solder, and screw connections are common methods for connecting wires to connectors, each with distinct characteristics.

Crimp connections involve mechanically compressing a wire into a metal contact using a specialized crimping tool. They are fast, reliable, and resistant to vibration, making them ideal for industrial and mass-production applications. The main drawback is that improper crimping can lead to poor electrical contact, and the process requires correct tooling.

Solder connections join wires to contacts by melting solder, creating a strong electrical bond. They are suitable for small or delicate wires and precise applications. However, soldering is time-consuming, sensitive to heat, and can become unreliable under constant vibration or mechanical stress.

Screw connections clamp the wire under a screw or terminal block, allowing easy installation, adjustment, and replacement. They are convenient for maintenance and prototyping. Their disadvantage is that screws can loosen over time, especially in high-vibration environments, and they are less suitable for high-density applications.

In summary, crimp connections are best for industrial reliability, solder connections for precision and delicate wires, and screw connections for flexibility and ease of service.

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FAQ

How to choose the right connector for my application?

Choosing the right connector essentially means balancing your application requirements with connector performance parameters.

1. Define the Application Scenario

Environment: indoor / outdoor / industrial / automotive / medical / consumer electronics
Operating conditions: temperature range, humidity, vibration, dust, water ingress, salt spray
Signal type: power / data / high-speed signal / RF / fiber optic

2. Electrical Performance Requirements

Current/voltage rating: maximum current capacity, rated voltage
Impedance requirements: for high-speed signals (USB, HDMI, Ethernet, RF)
Contact resistance: low resistance ensures signal stability
Shielding: need for EMI/RFI protection

3. Mechanical Performance Requirements

Mating cycles: e.g., USB > 5000 times, industrial connectors up to tens of thousands
Locking method: snap-fit, threaded, latch-type
Size & layout: space constraints (miniaturization / high-density layout)
Cable requirements: wire gauge, flexibility, exit direction

4. Environment & Certifications

Protection rating: IP65 / IP67 / IP68
Temperature range: high (>125℃) or low (<-40℃) temperature conditions
Flame-retardant rating: e.g., UL94 V-0
Industry standards: automotive (IATF 16949), medical (ISO 13485), industrial (IEC 61076)

5. Cost & Maintenance

Cost control: consumer electronics focus on price-performance, while industrial/aviation prioritize reliability
Replaceability: use of standard interfaces (RJ45, USB) for easier replacement
Supply chain stability: whether the brand can provide consistent supply and compatible models

Summary Recommendations:

For consumer electronics → focus on miniaturization, aesthetics, cost sensitivity; prioritize USB, Type-C, board-to-board (BTB) connectors.
For industrial applications → high reliability, waterproof, dustproof, vibration-resistant; choose M-series (M8, M12), heavy-duty connectors.
For automotive industry → consider high-temperature and vibration resistance; use automotive-grade connectors (e.g., TE, Amphenol).
For medical industry → biocompatibility and sterilization required; consider circular push-pull connectors (LEMO type).

What key parameters should be considered when selecting a connector?

When selecting a connector, the key parameters to consider are generally as follows:

1. Electrical Parameters

Current Rating: The maximum continuous current the connector can carry.
Voltage Rating: Maximum operating voltage.
Contact Resistance: Lower is better to ensure stable conduction.
Insulation Resistance: Ensures no leakage between signals/power.
Impedance Matching: Required for high-speed signals (e.g., USB, HDMI, Ethernet).

2. Mechanical Parameters

Mating Cycles: The number of times the connector can be plugged/unplugged, ranging from hundreds to tens of thousands.
Insertion/Withdrawal Force: Determines ease of use and reliability.
Size & Mounting: Through-hole / SMD, screw-fixed, snap-fit, etc.
Cable Compatibility: Supported wire gauge, shielding, and flexibility.

3. Environmental Parameters

Operating Temperature Range: e.g., -40℃ ~ 125℃.
Ingress Protection (IP): IP65 / IP67 / IP68 for dust and water resistance.
Vibration/Shock Resistance: Important for automotive and industrial applications.
Corrosion Resistance: e.g., salt spray testing.

4. Materials & Construction

Contact Material: Commonly copper alloys, with gold or tin plating for better conductivity and corrosion resistance.
Insulator Material: Common options include PBT, PA66, LCP; affects flame retardancy and strength.
Housing Material: Metal housing enhances shielding and strength; plastic housing is lighter and more cost-effective.

5. Standards & Certifications

Industry Standards: IEC, UL, MIL, automotive-grade (AEC-Q200).
Flame Retardancy Certification: UL94 V-0, etc.
Special Industry Requirements: Medical (biocompatibility), aerospace (lightweight + high reliability).

Summary:
In short, the most critical factors for connector selection are electrical performance (current/voltage/impedance) + mechanical reliability (mating cycles/mounting) + environmental adaptability (IP rating/temperature range) + materials & certifications.

How to Choose a Matching Connector Based on Cable Type and Size

Selecting a matching connector based on cable type and size requires considering conductor specifications, insulation and overall diameter, shielding structure, and application environment.

1. Determine Cable Specifications

Conductor Type: Copper, tinned copper, silver, or alloy; affects current carrying capacity and corrosion resistance.
Conductor Cross-Section / Gauge (AWG/mm²): Determines the connector’s current rating requirements.
Conductor Structure: Solid or stranded; stranded wires are more flexible and suitable for applications requiring frequent bending.

2. Confirm Cable Insulation and Overall Diameter

Insulation Thickness: Impacts the connector’s wire hole diameter and clamping capability.
Overall Diameter (OD): Ensures the connector’s pin, crimp, or clamping structure fits properly.

3. Consider Shielding Type

Unshielded Cable: Suitable for power or low-speed signals.
Shielded Cable: Required for high-speed signals or sensitive circuits; choose connectors that support shielding (e.g., metal shell or EMI grounding terminals).

4. Match Connector Type

Plug-in / Crimp / Solder:
- Crimp type is suitable for stranded flexible wires, easy to install, high reliability.
- Solder type works for solid wires or compact PCB connections.
Shape: Circular / Rectangular / Board-to-Board / Modular, selected according to cable and device interface.

5. Consider Environmental and Mechanical Requirements

Temperature & Humidity: Both cable and connector must operate reliably under working conditions.
Tensile and Bending Requirements: Ensure the connector’s latch or crimp can withstand cable pull and repeated bending.
Ingress Protection (IP): For outdoor or industrial environments, select connectors with matching waterproof/dustproof ratings.

Summary

Confirm the cable’s electrical specifications (current, gauge, conductor type).
Determine the physical dimensions (insulation thickness, OD, flexibility).
Choose a connector type according to signal type and shielding needs.
Finally, consider installation method, environmental suitability, and mechanical strength.

Are different series of connectors compatible with each other?

Whether different series of connectors are compatible depends heavily on their mechanical design, electrical characteristics, and intended standards.

1. Mechanical Compatibility

Pin Layout & Pitch: Different series often have different pin spacing (pitch) or number of pins. Mating a connector with mismatched pins can cause physical damage or unreliable connections.
Housing Shape & Locking Mechanism: Even if the pins line up, different series may have different latching, snap-fit, or screw mechanisms.
Board-to-Board or Cable-to-Board: Some series are designed for specific board thicknesses or cable diameters; mismatched series may not fit physically.

2. Electrical Compatibility

Voltage and Current Ratings: Each series has defined maximum voltage/current; mixing series may exceed ratings.
Impedance and Signal Type: High-speed signals (USB, HDMI, Ethernet) require impedance-matched connectors. Different series may have incompatible impedance, causing signal loss or reflection.
Contact Material and Plating: Different materials may have different corrosion resistance or conductivity, affecting reliability if connected together.

3. Standards & Series

Same Standard Series: Connectors within the same series (e.g., M12 A-coded, M12 B-coded) are usually compatible within their coding.
Different Series: Usually not compatible unless explicitly designed as backward-compatible (some industrial or modular connectors offer adapters).

Summary

Mechanical mismatch: Even slight differences in pin spacing or housing design can prevent mating.
Electrical mismatch: Different series may not support the same voltage, current, or signal requirements.
Practical rule: Only connectors within the same series or explicitly designed to mate across series should be used together. Using adapters is often the only safe way to connect different series.

What international standards do your connectors comply with?

Connectors typically comply with a range of international standards depending on their application (industrial, automotive, consumer electronics, medical, etc.). Here’s a structured overview of common standards:

1. Electrical and Mechanical Standards

IEC (International Electrotechnical Commission)
- Example: IEC 60512 – Connectors for electrical and electronic equipment; tests for mechanical and electrical performance.
UL (Underwriters Laboratories, USA)
- Example: UL 94 – Flammability of plastic materials.
- UL-listed connectors ensure safety compliance in North America.
CSA (Canadian Standards Association)
- Certification similar to UL, used in Canada.
MIL (Military Standards, USA)
- MIL-DTL-26482, MIL-DTL-38999 – High-reliability connectors for defense and aerospace applications.

2. Automotive Standards

AEC-Q200 – Automotive electronic components qualification.
ISO 16750 – Environmental testing for road vehicles (temperature, vibration, humidity).
SAE Standards – Automotive electrical connectors.

3. Industrial Standards

IEC 61076 – Circular and rectangular connectors for industrial automation.
IP Codes (IEC 60529) – Ingress protection (water and dust resistance).
RoHS / REACH – Environmental compliance for hazardous substances.

4. Medical and Aerospace Standards

ISO 13485 – Medical device quality management system; applicable for medical connectors.
EN 60601-1 – Safety standard for medical electrical equipment.
AS9100 / EN 3645 – Aerospace quality standards for connectors.

Summary
The exact standards your connectors comply with depend on:

Application – consumer, industrial, automotive, medical, aerospace.
Electrical & mechanical performance – rated current/voltage, mating cycles.
Environmental requirements – IP rating, temperature range, vibration resistance.

What is the IP Code for connectors?

The IP Code (Ingress Protection Code), sometimes called the International Protection Code, is a standardized rating system defined by IEC 60529 that indicates how well an electrical connector (or any enclosure) is protected against solids (like dust) and liquids (like water).

1. Structure of the IP Code

An IP Code has the format:

IP XY

X – Protection against solid objects (0–6)
Y – Protection against liquids (0–9K)

Example: IP67

2. Solid Object Protection (X)

Digit	Protection Level	Description
0	None	No protection
1	≥50 mm	Protected against large objects (hands)
2	≥12.5 mm	Fingers or similar objects
3	≥2.5 mm	Tools, wires, small objects
4	≥1 mm	Most wires, screws, small tools
5	Dust protected	Limited dust ingress allowed
6	Dust tight	No dust ingress

3. Liquid Protection (Y)

Digit	Protection Level	Description
0	None	No protection
1	Dripping water	Vertically dripping water
2	Dripping water (tilted 15°)	Vertically dripping water with slight tilt
3	Spraying water	Water sprayed up to 60° from vertical
4	Splashing water	Water splashed from any direction
5	Water jets	Low-pressure water jets from any direction
6	Powerful water jets	High-pressure water jets
6K	High-pressure, high-temperature jets	Industrial applications
7	Immersion up to 1 m	Temporary immersion
8	Immersion beyond 1 m	Continuous immersion under specified conditions
9K	High-pressure, high-temperature water jets	Severe cleaning processes

4. Practical Examples for Connectors

IP20 – Protected against fingers; no water protection. Typical for indoor PCB connectors.
IP65 – Dust-tight and protected against low-pressure water jets. Common for industrial circular connectors.
IP67 – Dust-tight and protected against temporary immersion. Common for outdoor and automotive connectors.
IP68 – Dust-tight and suitable for continuous immersion. Used in waterproof cable assemblies.

Summary
The IP Code helps you select connectors based on environmental protection requirements. When choosing a connector, match the IP rating to the dust and water exposure expected in your application.

What are momentary current and rated current, and what’s the difference?

Here’s a clear explanation of momentary current vs. rated current and their differences

1. Rated Current

Definition: The maximum continuous current that a connector (or any electrical component) can safely carry under normal operating conditions without overheating or degrading its performance.
Purpose: Ensures long-term reliability and prevents insulation or contact damage.
Example: A connector rated for 5 A can safely carry 5 A continuously at its specified voltage and temperature range.

2. Momentary Current (or Peak Current)

Definition: The maximum current the connector can withstand for a short duration (milliseconds to a few seconds) without damage.
Purpose: Allows for short-term surges or inrush currents, such as when motors start, capacitors charge, or devices switch on.
Example: A connector rated for 5 A continuous may tolerate 15 A for 1 second during startup.

3. Key Differences

Parameter	Rated Current	Momentary Current
Duration	Continuous	Short-term (milliseconds to seconds)
Purpose	Normal operation	Surges, inrush currents, temporary overloads
Thermal Effect	Must stay within safe temperature limits continuously	Can tolerate short-term heating without permanent damage
Specification	Mandatory in datasheet	Often specified as a peak or inrush current value

4. Practical Note

Always ensure the continuous current does not exceed the rated current.
Momentary current should only be considered for short-term events; exceeding it repeatedly or for long periods may damage the connector or reduce its lifespan.
For high inrush applications (motors, capacitors), choose a connector whose momentary current rating exceeds the expected surge.

How Can I Get a Quote and Samples?

We offer free connector samples for testing and evaluation to ensure our products meet your requirements. Request samples by contacting our sales team via the online form or email. For customized quotes, provide details like product Mode, quantity, and specifications. We typically respond within 24 hours with competitive pricing and support documentation.

What Is the Minimum Order Quantity (MOQ)?

Our MOQ is flexible, starting from 20 pieces for standard connectors. For custom designs, MOQ may vary based on complexity. We accommodate both small-batch orders and large-scale production to serve diverse global needs.

What Is Your Usual Lead Time?

（1）Stock products: Shipped within 1–3 days.
（2）Customized orders: Typically 4–8 weeks, depending on design and quantity. We prioritize urgent requests and provide real-time production updates to ensure timely delivery.

How Do I Request a Return or Exchange for a Defective Product?

We guarantee 30-day returns and exchanges for defective products. Contact our support team with order details and photos of the issue. Once approved, we cover return shipping and expedite replacements or refunds. Our process is transparent and customer-focused.

Help Overview

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Knowledebase

What are the basic components of a connector?