Detailed explanation of patch panel connector technology

1、 Overview

Terminal Block Connector is a core component in electronic and electrical systems that enables circuit connections, signal transmission, and power distribution. It is widely used in industrial control, home appliances, automotive electronics, communication base stations, and other fields. Its core function is to achieve reliable connection and insulation protection of conductors through mechanical structures, meeting the electrical performance and physical environmental requirements in different scenarios. The following text will systematically explain its technical characteristics, application areas, and design points.

2、 Core technical characteristics

1. Electrical performance

Rated current/voltage: Typical parameters are 5A-200A/50V-1000V, and industrial grade products can reach 300A/1500V

Contact resistance: ≤ 10m Ω (UL standard requirement ≤ 5m Ω @ 20A)

Insulation resistance: ≥ 100M Ω (500VDC test)

Voltage resistance: AC 2-4 kV/min (IEC 60664-1 standard)

Dielectric constant: Insulation material dielectric constant ≤ 4.0 (1MHz)

2. Mechanical characteristics

Plug and unplug lifespan: 500 times (regular model) to 10000 times (high reliability model)

Contact force: 0.5-5N (signal terminal) to 50N (high current terminal)

Wire specification: Supports wire diameter of 0.08-240mm ²

Vibration test: 10-2000Hz/50m/s ² (IEC 60068-2-6)

Impact test: 100g/6ms (MIL-STD-202G)

3. Environmental adaptability

Working temperature: -55 ℃ to+150 ℃ (special materials can reach+250 ℃)

Protection level: IP20 (basic type) to IP69K (fully sealed type)

Salt spray test: 96-1000 hours (ASTM B117)

Flame retardant rating: UL94 V-0 to V-2 (750 ℃ hot wire test)

3、 Typical application areas

Typical Model Examples of Core Requirements in Application Fields

Industrial automation anti vibration, high-density, dust-proof Phoenix PT 2.5-3-QUATTRO

Compact design of smart home appliances, quick plug and play WAGO 221 series

New energy vehicles with high current carrying capacity, high temperature resistance, EMC shielding TE AMP+HVA 280 series

Weidm ü ller TOPJOB S series photovoltaic inverter DC withstand voltage and arc prevention design

Medical equipment sterile environment compatible, low leakage current Molex MediSpec ™ Sealed connector

4、 Product classification and structural characteristics

1. Classified by current capacity

Micro terminal (≤ 5A): 0.08-0.5mm ² wire diameter, spacing 2.5-3.5mm

Standard type (5-40A): 1.5-6mm ², spacing 5.08mm

High current type (40-300A): 16-240mm ², double-layer conductive bridge structure

2. Classify by connection method

Screw type: Torque range 0.2-2.5N · m, supports aluminum/copper wires

Spring type: tool free operation, with a 70% increase in insertion and removal speed

Insulation puncture type: insulation layer thickness ≤ 0.8mm, contact resistance fluctuation<10%

Crimp type: with AMP crimping tool, the crimping force is 20-200kg

3. Classified by protection level

Open type (IP20): used for conventional control cabinets

Protective type (IP54/IP65): with silicone sealing ring and drainage structure

5、 Key material system

1. Conductor material

Copper alloy: C5191 phosphor bronze (conductivity ≥ 20% IACS)

Composite coating: Ag/Ni (3 μ m/1 μ m) reduces insertion force by 30%

High conductivity aluminum: applied to new energy vehicles (conductivity 62% IACS)

2. Insulation materials

Comparison of temperature resistance range characteristics of material types

PA66 has low cost, easy processing, and excellent arc resistance at -40~120 ℃

PBT has high dimensional stability at -40~140 ℃ and is resistant to hydrolysis

LCP -50~240 ℃ ultra-thin wall forming (0.2mm)

PPS is resistant to chemical corrosion at -40~220 ℃, CTI≥600V

3. Shell material

Engineering plastic: 30% fiberglass reinforced nylon (UL94 V-0)

Metal shell: ADC12 aluminum alloy anodized treatment

Sealing material: liquid silicone rubber (hardness 30-80 Shore A)

6、 Welding process parameters

1. Wave soldering process

Preheating zone: 80-130 ℃ (heating slope ≤ 3 ℃/s)

Welding temperature: 245-260 ℃ (SnAgCu lead-free solder)

Contact time: 3-5 seconds (pin tin depth ≥ 0.8mm)

2. Reflow soldering curve

Stage temperature range time control

Preheat to 150-180 ℃ for 60-90s

Soaking at 183-220 ℃ for 40-70s

Peak value 235-245 ℃ 20-40s

Cooling rate<5 ℃/s to avoid thermal stress cracks

3. Key points of manual welding

Soldering iron power: 30-60W (grounded soldering iron)

Temperature control: 320 ± 20 ℃ (lead solder)

Welding time: ≤ 3 seconds per pin (to prevent deformation of the plastic shell)