- The need for compact, reliable interconnects extends beyond
automotive to permeate consumer electronics, industrial automation,
medical devices and smart agriculture
- Blending the best of miniaturization and ruggedization
improves space efficiency, reliability, design flexibility, signal
integrity and thermal management
- Advanced materials science, innovative design techniques and
evolving manufacturing processes reduce roadblocks to reshape
next-generation compact, durable connectors
LISLE,
Ill., June 25, 2024 /PRNewswire/
-- Molex, a global electronics leader and connectivity
innovator, has released a report that explores the
ever-increasing role of ruggedized, miniaturized interconnect
solutions in unlocking new possibilities for electronic device
innovation across a growing swath of industries. The report,
entitled "Breaking Boundaries: Uniting Ruggedization and
Miniaturization in Connector Design," looks at the trends,
tradeoffs and enabling technologies that remove roadblocks while
helping shape the future of electronics.
"Increasing demand for electronics in new vehicle
platforms has intensified the need for smaller and rugged
interconnects designed to withstand the harshest environments,"
said Carrieanne Piccard, VP and GM,
Transportation Innovative Solutions, Molex. "As a result, the
ruggedization of miniaturized connectors has emerged as an
overarching design principle, requiring a holistic approach across
the entire lifecycle of components to achieve optimal product
reliability, performance and longevity."
Critical Connectivity Enablers
In this
industry report, Molex defines miniature connectors as having a
pitch of 2.54mm or less while ruggedness refers to features for
withstanding the harshest environments and mechanical stresses. The
convergence of interconnect ruggedization and miniaturization has
enabled major innovations in the automotive industry, especially in
supporting electric vehicles (EVs) and zonal architectures. Now the
trend is permeating other industries, including consumer
electronics (e.g., fitness trackers, smartwatches and smart home
devices); industrial automation (e.g., industrial robots,
touchscreens and sensors); as well as medical devices (e.g.,
endoscopes, insulin pumps and wearable health monitors).
Growing adoption of compact, durable connectors
is gaining traction in other application areas, such as smart
agriculture. Vertical farming systems with dense sensor and
lighting installations require space-efficient connectors that work
in wet, humid environments without interruption. Smaller, lighter
and rugged connectors found in agricultural drones or "flying
tractors" also must be protected against extreme temperature and
excessive vibration, along with exposure to moisture, dust and
corrosive chemicals.
Pushing Design Boundaries
Molex's new
report explores best practices for clearing major design and
manufacturing roadblocks to facilitate the design of increasingly
smaller, lighter and more reliable connectors. Aluminum alloys and
specialized, high-strength steel, as well as high-performance
polymers, offer exceptional durability and lightweight
construction. Processing these materials into complex connector
geometries, however, often calls for specialized techniques,
ranging from micro-molding and high-precision machining to laser
welding or selective plating.
In addition, dense pitch layouts enable
higher-contact density to accommodate smaller device footprints,
but they require high-precision manufacturing and assembly.
Increased risk of crosstalk and ineffective heat dissipation also
can occur. To mitigate these issues, engineers can rely on advanced
signal routing techniques, shielding and isolation methods, along
with advanced thermal management strategies like heat sinks or
thermal vias. Molex DuraClik Connectors feature housings made
from high-temperature PBT material and secure terminal retention to
withstand extreme automotive environments.
Multi-Functional Terminals (MFTs) represent a
significant leap forward in miniaturized connector technology by
integrating multiple functionalities — power, signal and even
mechanical features, like locking mechanisms, into a single compact
connector. Molex's new report also investigates top environmental
factors that can compromise component reliability while offering
strategies and solutions to ensure optimal connector performance in
harsh conditions. Strain relief features and contact design help
optimize connector performance despite constant exposure to the
stresses of vibration, shock and repeated mating cycles.
At Molex's Global Reliability Lab, engineers
simulate real-world vibration, temperature cycling and exposure to
harsh chemicals. Molex Micro-Lock Plus Connectors address vibration
challenges with a positive locking mechanism to ensure secure
mating while averting accidental uncoupling in high-vibration
environments. The connector's metal solder tabs provide added
strain relief to solder joints for enhanced resistance to
mechanical stress and vibration.
Since even a single drop of water or speck of
dust can create corrosion, shorts, and ultimately, device failure,
ingress protection is essential. Molex's Squba
Connectors feature IP68-rated seals certified as resistant to
nearly five feet of water for 30 minutes. These compact connectors
optimize power delivery in one of the smallest, most durable form
factors available.
As devices continue to shrink in size yet grow in
functionality, Molex engineers are pushing the design boundaries of
miniaturization and ruggedization to solve real-world business
problems and exceed customer expectations.
About Molex
Molex is a global
electronics leader committed to making the world a better, more
connected place. With presence in more than 40
countries, Molex enables transformative technology innovation in
the automotive, data center, industrial automation, healthcare, 5G,
cloud and consumer device industries. Through trusted customer and
industry relationships, unrivaled engineering expertise, and
product quality and reliability, Molex realizes the infinite
potential of Creating Connections for Life. For more
information, visit www.molex.com.
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SOURCE Molex Incorporated