Environmental Performance: Common environmental performance requirements include resistance to temperature, humidity, salt spray, vibration, and shock.
① The maximum operating temperature of heat-resistant connectors is 200°C (except for a few special high-temperature connectors) and the minimum is -65°C. Since current generates heat at the contact points during connector operation, causing a temperature rise, the operating temperature is generally considered to be equal to the sum of the ambient temperature and the contact temperature rise. Some specifications specify the maximum allowable temperature rise for connectors at rated operating current.
② Moisture Resistance: Moisture intrusion can affect the insulation performance of the connection and corrode metal parts. The steady-state damp heat test conditions are 90% to 95% relative humidity (up to 98% depending on the product specification) and a temperature of +40°C ± 20°C. The test duration is specified as a minimum of 96 hours, as specified by the product. Alternating damp heat tests are more stringent.
③ When operating in environments containing moisture and salt, salt spray-resistant connectors may suffer from galvanic corrosion of the metal components and contact surface treatment, affecting the physical and electrical performance of the connector. To evaluate the ability of electrical connectors to withstand such environments, salt spray testing is specified. The connector is suspended in a temperature-controlled test chamber and a sodium chloride solution of a specified concentration is sprayed with compressed air to create a salt spray atmosphere. The exposure time is specified in the product specification and must be at least 48 hours.
④ Vibration and Shock Resistance: Vibration and shock resistance are important performance characteristics of electrical connectors, particularly in specialized applications such as aviation and aerospace, and rail and road transportation. They serve as key indicators for verifying the robustness of the mechanical structure and the reliability of electrical contacts. These requirements are clearly defined in the relevant test methods. The peak acceleration, duration, and shock pulse waveform of the shock test should be specified, as well as the time it takes for electrical continuity to be interrupted.
⑤ Other Environmental Performance: Depending on the intended use, other environmental performance characteristics of electrical connectors may include sealing (air leakage, liquid pressure), liquid immersion (resistance to degradation by specific liquids), and low air pressure.
