Optimizing force and geometry parameters in design of reduced insertion force connectors

Nine test connector designs fabricated with 150-, 75-, and 35-g nominal contact normal force and with 150-, 70-, and 35-mil radii at the point of contact with the pin were examined. The connectors were exposed to conditions of thermal stress (thermal aging and thermal cycling), atmospheric corrosion, and extreme dust contamination coupled with thermal/humidity exposure. Precision resistance measurements were made at various times before, during, and after the stress exposures. All nine designs performed reliably under the test conditions used. The results suggest that connectors designed with contact geometries that provide higher local pressures are more effective in overcoming the interference of the dust contamination