Connectors and cables get smaller and tougher

In 2024, interconnect manufacturers focused on ruggedizing their connectors and cable assemblies and making them smaller. While manufacturers of connectors and cables have always faced the demand for more robust designs for automotive, industrial, medical and military/aerospace applications, these demands are now shifting into other industry segments, including consumer electronics, communications and data centers.

A recent Molex report, “Breaking Boundaries: Uniting Ruggedization and Miniaturization in Connector Design,” finds that the combination of ruggedization and miniaturization has enabled major innovations across industries. Though primarily driven by increasing demand for electronics in new vehicle platforms that are packed with wiring, sensors, cameras, processors and other components in space-constrained spaces, the need for ruggedized and miniaturized interconnects is extending into other market segments, including consumer electronics, industrial automation, medical devices and smart agriculture.

In addition, OEMs are looking for greater flexibility in their designs and ways to reduce costs. Here are a few examples of connectors and cables introduced this year that meet their requirements. These include miniaturization for space and cost savings and ruggedization, including longer life and higher corrosion and vibration resistance, as well as higher operating temperature ranges. Many also offer a wide range of options for greater design flexibility.

Board-to-board connectors

Amphenol Communications Solutions recently introduced the DensiStak board-to-board connector line of high-density and compact interconnects, especially for challenging environments such as automotive. They can also be used in a range of other applications, including data centers, telecommunications and industrial.

Delivering a flexible pin design and a high pin-count density, the DensiStak connector features over 1,000 pins arranged in an 11-row configuration to meet high-density application requirements such as the main interface to an automotive electronic module, dealing with complex computations like autonomous driving, and data rates up to 16 Gbits/s on PCIe Gen 4.

Other features include a dual-beam contact system, USCAR-2 T3V2 certification, supporting temperature class T3 up to 125°C; shock and vibration class V2; an open-pin-field array design for greater flexibility; and optional shields. It is also housed in a small form factor (0.80 × 1.25 mm) to optimize board space, especially for densely populated systems.

Amphenol said the dual-beam contact design enhances reliability with redundant electrical paths, which minimizes the risk of signal interruption due to shock, vibration or environmental factors.

Harwin introduced fine-pitch, high-pin-count board-to-board connectors, offering high-speed data transmission and mixed-signal and power options. The new Flecto floating connector family offers up to 160 contacts in a symmetrical, double-row layout and is available with three choices of miniature pitches: 0.5 mm (.0197 inches), 0.635 mm (.025 inches) and 0.8 mm (0.0315 inches). Target applications include factory automation, electric vehicles, LED displays, security cameras, IoT devices, data communications and a variety of embedded systems.

The Flecto floating connectors also handle small movements in multiple axes to support high-speed automated assembly and improve resistance to shock and vibration during operational life. By accommodating up to ±0.5-mm movement in both the X and Y axes, it enables accurate placement of multiple connectors between the same two PCBs, where the sum of misalignments could result in challenges for high-speed, high-precision mating, according to the company.

The positional-tolerance flexibility also enhances system reliability, Harwin said, by maintaining connection integrity during shock and vibration and reducing the possibility of degradation or failure from fretting, which occurs when long-term vibration causes plating to wear from rigid mating pins, exposing the underlying alloy to potential oxidation.

Flecto connectors support board-to-board mating heights as low as 7.2 mm and data rates as high as 12 Gbits/s. Additional power pins available with the 0.5-mm-pitch options are rated for currents up to 3 A. Vertical and horizontal female connectors allow boards to be connected in parallel or at right angles to each other.

Flecto signal-only connectors feature either location pegs or posts to eliminate movement during solder reflow. Mixed-signal and power connectors feature through-board solderable posts for location accuracy and enhanced mechanical strength. A range of connectors feature shrouded contacts to prevent accidental damage when no mating connector is present, while others offer polarization within the shroud to ensure unidirectional mating.

Samtec Inc. has extended its family of Edge Rate board-to-board connectors with a higher-density mated set that is half the width of previous designs with a lower profile. The new ERF6 (socket) and ERM6 (header) Series connectors also offer a lower-profile, 5-mm mated height. These connectors support 56-Gbits/s PAM4 high-speed, rugged mezzanine applications for industrial, embedded vision, instrumentation and monitoring, drones and robotics.

The ERF6 and ERM6 connectors feature two rows of pins with an extremely narrow body width of 2.5 mm. The connectors are available in body lengths from 11 mm to 42.8 mm with a 0.635-mm centerline. Available positions for each row are 10, 20, 30, 40, 50 or 60. These features enable easy customization while still allowing for quick delivery, Samtec said. Weld tabs are available within the standard part number configuration for applications in which pull and shear force are a concern.

Despite its low profile, the connectors still allow 0.90 mm of nominal contact wipe for a reliable connection, Samtec said. They provide polarizing features that are molded into the connector body to ensure the connectors are aligned properly and allow for angular and linear misalignment, as shown in the product spec sheet.

The Edge Rate connectors use a unique contact system that is reported to extend cycle life, increase durability and lower insertion and withdrawal forces, as well as deliver “superior” electrical performance compared with traditional stamped contacts. Samtec attributes these benefits to the use of the flat, smooth-milled side of the contact for the mating surface instead of the cut edge, which can have rough microscopic edges and burrs.

In addition, the narrow edge of the contacts is aligned within the connector body to reduce broadside coupling and crosstalk, Samtec said.

Hybrid connector systems

Molex’s new MX-DaSH family of data-signal hybrid connectors, combining power, signal and high-speed data connectivity in a single connector system, targets next-generation automotive architectures. They are designed to reduce wire harness costs and weight as well as complexity.

These wire-to-wire and wire-to-board connectors support the transition to zonal architectures and address emerging applications that require reliable data transmission. These include autonomous-driving modules, camera systems, GPS and infotainment devices, LiDAR, high-resolution displays and sensor-device connectivity.

In addition to offering savings in size, space and cost by integrating power and high-speed data transmission in a single connector system, the MX-DaSH family offers greater design flexibility with different terminal types and sizes, allowing designers to mix and match connectors across different vehicle designs and applications.

The MX-DaSH connectors are available with sealed and unsealed options to meet different environmental and design requirements. Configurations support different power and signal terminal sizes, such as 0.50, 0.64, 1.20, 1.50, 2.80 or 4.80 mm, as well as high-speed FAKRA Mini modules for high-speed data transmission.

For greater reliability, MX-DaSH wire-to-wire connectors feature male blade stabilization and independent secondary locks for reliable terminal mating. These connectors also offer modular sections or cartridges in the wire-to-board option that support various interfaces without changing form factors or footprints. This enables automotive engineers to accommodate a growing mix of devices and sensors with different network requirements, Molex said.

Multiple options in the connector system include a variety of wire-to-wire applications. One example is the 31+1-Way connector system that combines 31 power and ground circuits, as well as a high-speed data connection, to decrease packaging requirements by up to 30%, Molex said. This higher functionality translates into time savings through streamlined harness installations, while fewer component requirements offer a further reduction in the bill of materials.

The MX-DaSH connectors have been validated in accordance with global industry standards groups, including USCAR, Peugeot and IEC, to ensure reliable performance in harsh automotive environmental conditions.

Also enabling next-generation vehicle architectures is TE Connectivity’s new NET-AX+ modular hybrid connector system. This solution integrates coaxial and differential data ports with signal and power connections in a single, compact connector assembly.

Featuring a chiclet-based building-block design with a customizable and modular header design, the NET-AX+ modular hybrid connector system offers up to a 40% reduction in PCB footprint, 80% fewer mating assemblies and optimized installation space for the harness connector. It enables speeds up to 56 Gbits/s, meeting requirements for both the current and next generation of electrical/electronic architectures to support Ethernet and SerDes applications in next-generation vehicles.

USB connectors for challenging environments

Fischer Connectors has expanded its high-speed data connector line with rugged solutions using the USB 3.2 Gen 2 protocol up to 10 Gbits/s. These high-speed connectors target a range of applications, including surgical equipment; small computers and peripherals for soldiers; outdoor test and measurement applications; and civil and military drones.

Fischer has developed USB 3.2 connectors and cable assembly solutions in three of its flagship product lines (Core Series, MiniMax Series and UltiMate Series) to meet signal integrity and harsh environment requirements for medical, defense, industrial and instrumentation applications.

The three series offer IP68 sealing (IP69 and hermeticity with a resin-sealed contact block for Core and UltiMate), extreme operating temperatures (MiniMax from –40°C to 135°C, Core from –70°C to 250°C, UltiMate from –55°C to 135°C), high mating cycles (MiniMax up to 5,000; Core and UltiMate up to 10,000) and three locking mechanisms: push-pull and quick release for the three series, plus screw for MiniMax. UltiMate also allows for blind mating with robust mechanical keying.

Targeting surgical equipment and instrumentation applications, the Core Series connectors are highly customizable and resistant to chemicals and sterilization processes. The MiniMax Series targets applications in which size, weight and power are critical, such as miniature body-worn computers and peripherals, high-performance LiDAR and high-speed intercom boxes. These ultra-miniature, high-density connectors offer a unique combination of signal and power and can combine multiple protocols into one connector.

The UltiMate Series offers rugged, compact, lightweight and sealed connectors, suited for extreme applications that require high resistance to shock and vibration. It also offers corrosion resistance up to 1,000 hours of salt mist. Applications include civil and military drones equipped with USB3 cameras and mil-spec applications.

Earlier this year, Amphenol Socapex released a ruggedized USB Type-C connector, based on the MIL-DTL-38999 series III standard. The new USB3CFTV is designed to withstand harsh environments and demanding applications such as military communications, military planes, aerospace, commercial air and naval applications. It can be used in a range of data, power delivery and video configurations.

The USB3CFTV addresses harsh environment applications that need the flexibility of a USB Type-C connector. The connector features a Tri-start thread-coupling mechanism that ensures resistance to shock, vibration and cable traction. It also features a high level of sealing protection from external fluids and dust exposure, up to IP68.

The connector’s shell size 11 and shock, vibration and traction resistance make it durable in demanding applications, the company said. It features 500 mating plug/receptacle cycles and operates over the temperature range of –40°C to 85°C.

The connector is fully reversible, which allows for bidirectional power capabilities, and it is compatible with USB 3.2 specifications. It features a power supply of up to 100 W (20 V/5 A) for demanding power requirements and supports data transmission of up to 1 meter.

The USB3CFTV connector also provides enhanced electromagnetic-interference (EMI) protection and is available in a range of materials and coatings that are compliant with a variety of environmental regulations. This makes it suitable for use in applications with extreme temperatures and harsh chemical environments.

Space-saving connectors

Targeting space-constrained applications, Hirose Electric Co. Ltd. has introduced back-flip FPC/FFC connectors with a 0.5-mm-pitch version that offers dual-contact functionality to simplify flex routing. The TF07V Series saves board space with a height of 2.1 mm, making it suited for consumer electronics, industrial robotics and medical applications that require miniature and rugged connectivity solutions.

Hirose said the new connectors offer space savings without sacrificing performance or durability. Offering higher reliability, the top- and bottom-contact design provides board design flexibility and ease of assembly, while the back-flip design increases the FPC/FFC retention in the vertical direction. The back-flip design is also impervious to debris, preventing any unexpected actuator openings after installation.

Compared with front-flip connectors, the TF07V Series is reported to offer a higher retention force and protection during installation. With the back-flip design, these connectors are delivered with the actuator open, and mating is completed in two steps of FPC/FFC insertion and closing the actuator.

The TF07V Series is available in 30, 40, 50 and 60 positions. The rated current is 0.5 A and the rated voltage is 50 VAC/VDC. The operating temperature range is –40°C to 85°C.

TE Connectivity recently released a line of compact elbow connectors for smaller switchgears, which require more space-efficient connectivity. TE’s Raychem ELBA asymmetric compact elbow connector can cut stacking length by 40%. It also offers increased range and installation flexibility. One standard body size can cover up to 1,500 Kcmil, making it possible to use a single unit rather than two, streamlining the design and installation process.

It is TE’s first compact connector compatible with smart voltage-detection systems to be certified to IEEE 386-2016 standards. The flexible installation suits it for wind farms, data centers, solar farms, underground power networks and other facilities where space is tight and rapid project rollout is crucial, TE said.

These compact elbow connectors can be configured as a single stack, a double stack with a coupling connector, a triple stack with a coupling connector and surge arrestor, or a smart stack with voltage detection. They can be deployed underground as disconnectable inline joints or as a double connection.

The cable cutback preparation is the same as with standard IEEE elbow connectors, requiring no additional training, TE said. The lead-free, peroxide-cured EPDM body supports the connector’s resilience, improved insulation and long service life.

Cable assemblies get smaller, offer more options

Samtec Inc.’s fully shielded NovaRay cable assemblies deliver PAM4 signals in dense designs. Offering “extreme” density by using 40% less space than traditional arrays to support 112-Gbits/s PAM4 per channel, these cable assemblies target applications in datacom, AI/ML, HPC, computers and semiconductors, medical, test and measurement, military/aerospace and mobile networks.

The fully shielded differential-pair design of the cable assemblies enables extremely low crosstalk and tight impedance control, Samtec said. In addition, the combination of the differential-pair design with two reliable points of contact contributes to the 4.0-Tbits/s aggregate data rate.

The cable assemblies provide low, <30-dB (FEXT and NEXT) crosstalk out to 40 GHz. They operate across a temperature range of –40°C to 125˚°C and are PCIe 6.0–/CXL 3.1–capable.

The NovaRay cable assemblies offer several configurations. These include one or two banks, with two, three or four rows. The cable assemblies offer eight to 32 differential pairs. Up to 72 pairs (six rows, three banks) are in development.

The NovaRay cable assemblies include two connectors and are available with optional shielding and latching systems. End 1 of the cable assembly includes a NovaRay connector, while a variety of End 2 options are available, including FQSFP, NovaRay I/O, ExaMAX backplane and the upcoming NovaRay backplane, depending on the application.

The cable assemblies are available with 34 AWG EyeSpeed ultra-low-skew twinax cable (<3.5 ps/meter). Options include 34 AWG/100 Ω, 34 AWG/92 Ω and 34 AWG Thinax/92-Ω ultra-performance cable (with a 40% smaller cross-sectional area). The 92-Ω solutions address both 85-Ω and 100-Ω applications.

L-com, an Infinite Electronics brand, has expanded its line of IX industrial Ethernet cables with angled connectors, offering high-flex, low-smoke zero-halogen (LSZH) and economy versions. These include outdoor and high-flex industrial, CMX LSZH and CMR PVC economy jacket types. Each version comes in lengths of 1 meter or 3 meters.

These Cat 6a cable assemblies with angled connectors are suited for space-constrained applications with tight cable routing challenges. Target applications include factory and other industrial settings, especially security and machine-vision cameras.

The new Ethernet cable line is rated IX industrial Type A for 10G Ethernet in harsh environments. They all use 26 AWG wire and are SF/UTP or F/UTP shielded for protection against EMI and radio-frequency interference. They are 100% power-over-Ethernet-capable and -compatible.

The outdoor and high-flex industrial assemblies offer three configurations: a down-angle IX A plug on one end and options for an IX A plug, RJ-45 jack or RJ-45 plug on the other end. A thermoplastic elastomer outer jacket provides chemical resistance and temperature tolerance while offering flexibility and durability.

The LSZH cable assemblies feature six configurations: a down-angle IX A plug to an IX A plug, RJ-45 jack or RJ-45 plug; and an up-angle IX A plug to an IX A plug, RJ-45 jack or RJ-45 plug. The flame-retardant jacket is rated CMX LSZH for low-smoke emission, zero halogens and reduced toxicity in the event of a fire.

The economy cable assemblies are also available in six configurations: a down-angle IX A plug to an IX A plug, RJ-45 jack or RJ-45 plug; and an up-angle IX A plug to an IX A plug, RJ-45 jack or RJ-45 plug. These assemblies are protected with a PVC outer jacket and are CMR-/CMX-rated.

Stewart Connector, a Bel group company, offers single-pair Ethernet (SPE) jacks and cables that meet the connectivity component standard IEC 63171-1. SPE enables data as well as power transmission via power over data line, with transmission speeds of up to 1000Base-T1 over one pair of copper wires.

Stewart said this space-saving, lightweight design reduces complexity and provides extended reach over traditional four-pair wiring systems. They are suited for smart buildings and building automation, including Ethernet switches, HVAC controls and sensors, intelligent lighting, security systems and access controllers.

The SPE jacks and cables have an operating temperature of –20°C to 60°C and can support 1000Base-T1, 100Base-T1, 10Base-T1L and 10Base-T1S. They feature a shielded design for improved EMC performance, are made using UL 94V-0 halogen-free plastic components, and are RoHS-compliant. Cables are easily customized for 5, 10 and 15 meters and other specified cable lengths on request. An optional light pipe for port status indicators when used in combination with a PCB-mount LED is available.