What is a connector?

Electrical circuits are composed of various components that include cables and wires. The electrical connectors join all of these components to provide a continuous way to ensure the proper flow of electric current.  An electrical conductor is an electromechanical device responsible for creating an electrical circuit by joining the electrical conductors. These electrical connectors are either a female socket or a component to the male connector, known as the plug. This connection is usually removable. It requires a tool for the removal and assembly and serves as an electrical joint among both the points permanently. In computing, these electrical connectors serve as a physical platform and integral part of the physical layer present in the OSI model for networking (Mroczkowski, 1998).  

How is a connector made?

The making of the connectors is a process of four main steps such as:

Stamping: Thin strips of metal stamp the connectors by high-speed punching machines.

Plating: Right after the stamping process, the pins are sent to the plating area, where the contact surface of the connector is plated with coatings of different metals.

Injection: The housing, made of plastic, of the connector, is manufactured during the injection stage. The method involves the injection of molten plastic into a metallic film and then cooling it quickly.

Assembly: The last stage of connector manufacturing is the finished assembly. There are two available methods for the insertion of plated pins in the injection holder of the cassette, i.e., the combined (it involves combining several pins with the holder altogether) and the single inserts (it involves the insertion of a single pin at a time) (Mroczkowski, 1998).

What are different types of connectors?

Dissimilar connectors can be joined using an adapter. There are multiple connectors available, and they are for the sole purpose of audiovisual, data, and power applications. We can distinguish various electrical connectors based on their function, type of termination, and level. Based on their points of termination, they can be classified as follows.

  • Board-to-board connectors

These connectors connect the PCBs without using a cable. These connectors are used for space optimization since no cables are required, making them ideal for systems with insufficient space. The PCBs can be connected in a perpendicular or parallel configuration. The connector that connects the PCBs in any configuration for collecting them together is known as the mezzanine connector. This term is to define the side-by-side or perpendicular arrangements of PCB. These arrangements are quite common for parallel management, mainly for the daughterboard-motherboard provisions.

  • Wire/Cable-to-Wire/Cable Connectors

As the term identifies, these connectors are for the connection of two wires. One of the ends is connected to the wire permanently, and the other one produces a separable border. The permanent connection can be attained by the IDC (Insulation Displacement Contact) or by crimping. In the IDC method, we achieve the connection by insulated wire insertion into the slot of the beam that is a sharpened metal. These edges cut through the insulation and make contact between the wires, i.e., between the beam and the wire. In the case of crimping, it is usually applied for the discrete connection among wires.

  • Wire/Cable-to-Board Connectors

As suggested by the connector’s name, it connects the cable or a wire to the PCB. These wire connections are a lot like the board and wire. They can also be soldered by the connectors of two-piece or pressed together. Apart from these, there are some versions of card edges that are still in use these days. The interface connecting the connections might be similar to the wire-to-wire connector for the family of the product (Connector Basics: Three Types of Electrical Connectors, 2021).  

How does a connector work?

Connectors provide a platform between the instrument they are serving and the cables. Each device utilizes distinctive signal processes for delivering high-quality data flow and the information to other relevant units when required, even with different current flow and voltages. These connectors consist of pins that maintain low resistance and flexibility. We make these pins using tempered beryllium copper and slide them into small tubular sockets inside the body of the connector. These pins are generally micro in size, placed at a pitch of 1.27mm, while the Nano-size connectors are even more miniature, i.e., of 0.635mm (Kirsh, 2018).

What are the applications of a connector?

The applications of connectors are various in many industries with multiple purposes of usage:

Automation of industries, Transportation, Embedded system, Communication, Datacom, Medical technology, Military technology, Automotive, Control and measure technology, Instrumentation

Who manufactures connectors?

The top manufacturers of connectors based in the United States are Rosenberger, Yazaki, TE Connectivity, Molex, Amphenol, Foxconn, JST, JAE, Aptiv, and Luxshare precision. 

Where to buy connectors?

In addition to the various electronic components, BD electronics Ltd provides customers with high-quality connectors to ensure delivery to be as fast as possible. Hence, the company makes sure that the customers receive their requirements in the best way possible. Apart from the connectors, the company offers various electronic components that the customers can get as per their requirements. We make sure to provide the customers with the best possible service at reasonable prices. The factors that create our competitive edge over our competitors are fast and efficient delivery services and the maintenance of high standards in terms of our customers’ functionality and satisfaction. We ensure their demands are met within the shortest possible lead time.

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