TTI’s business development manager, Steve Brahosky, discusses the environmental conditions that interconnects face and how their design determines their survival.
‘Neither snow nor rain nor heat nor gloom of night …’ Well, you know the rest. According to the famous (albeit unofficial) US Postal Service motto, the mail delivery will not be deterred by such extreme circumstances. Those same kinds of harsh conditions, and many others, threaten today’s electronic connectors and the reliable performance they must deliver.
Modern electronic systems are now used for more applications than ever—in a wider variety of industries and rougher environments. These include everything from aerospace/defense to waste management to robotics—in settings from high altitudes to underwater to the factory floor.
Whether in natural or controlled environments, connectors and the sensitive electronics they protect are increasingly exposed to potential damage. However, design considerations are ongoing and continually improving connectors to withstand these conditions.
Thermal stress
Extreme temperatures cause problems. Highs create thermal expansion, leading to degradation of materials, while lows make materials brittle. Also, thermal cycling (exposure to both) significantly affects connectors’ properties over time. Use materials with high thermal stability and low coefficient of expansion to minimize thermal stress.
Humidity and moisture
Exposure to humidity or moisture can lead to corrosion and degradation of electrical characteristics and possible failure. Use sealing materials and techniques such as O-rings and gaskets, to achieve high IP and prevent moisture from entering—IP67 or IP68 ratings (waterproof up to certain depth). Hermetically sealed connectors provide absolute protection.
Corrosion and contaminants
Exposure to saltwater, industrial chemicals or acids can accelerate corrosion of metals, leading to poor signal transmission and connector failure. Use corrosion-resistant materials such as stainless steel, titanium, gold and nickel-plated metals and polymer-based materials like Teflon, PEEK, and other high-performance polymers that are chemically resistant and non-corrosive.
Mechanical stress and vibration
High levels of vibration or mechanical shock (impact, earthquake, explosion etc) can cause fatigue failure, intermittencies and connector separation. Use strong mechanical mounting and latching mechanisms and flexible materials. Strain-reliefs absorb external forces and are crucial for ruggedized connectors, along with retention clips to help prevent disconnections.
Electromagnetic interference
Environments with high levels of electromagnetic interference (EMI), due to proximity to multiple electronic devices, can degrade performance or cause data transmission errors. Metal shielding of interconnects, along with wires/cables and proper grounding, will prevent EMI. Using ferrite beads (which act as low pass filters) or embedding EMI filters in the connectors can also help mitigate its effect.
Altitude and pressure
In high-altitude environments, such as space, low pressure can cause out-gassing of materials, which reduces insulation properties, allowing condensation and leading to connector failure. Environments with high pressure, such as underwater, can compromise the integrity of connections and cause mechanical deformation. Use seals, such as O-rings, gaskets or compression seals, which can withstand pressure differential between internal and external pressures. Flexible, lightweight seals made of neoprene or silicon might be sufficient for low-pressure environments. Hermetically sealed connectors are required for space environments.
Interconnect solutions designed to withstand extreme conditions produce tremendous benefits: increased reliability and durability, extended operational lifespan, application versatility, reduced downtime and substantial long-term cost savings.
TTI takes pride in guiding its partners to the best technology available for their needs, sourcing connectors built specifically for harsh environments. The company brings decades of combined experience to the table to deliver exactly what is most appropriate for each scenario today and going forward.
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