Board-to-board (BTB) connectors provide electrical connectivity and mechanical stability across stacked, parallel, or orthogonal printed circuit board (PCB) configurations. Reliable connector engagement requires managing cumulative tolerances from PCB fabrication, component placement, solder reflow, and thermal cycling. Without effective alignment strategies, tolerance stack-up can prevent proper mating, stress solder joints, and degrade signal integrity. This tutorial […]
FAQ
How 800 V+ architectures impact EV connector and contactor requirements
Electric vehicle (EV) architectures operating at 800 V and above deliver measurable efficiency gains by reducing current for a given power level. Because resistive losses scale with the square of current, lower current reduces conduction losses across cables, busbars, and switching components. At the same time, higher bus voltage shifts design constraints across the entire […]
How are impedance mismatches at connector interfaces handled in mixed-voltage EV architectures?
In electric vehicle (EV) architectures, high-voltage (HV) traction systems coexist with low-voltage (LV) high-speed data networks, such as Automotive Ethernet. This configuration creates a complex electromagnetic environment in which impedance mismatches at connector interfaces can lead to signal degradation, electromagnetic interference (EMI) noncompliance, and power loss. This FAQ outlines the technical methods used to identify […]
How to keep connectors from ruining high-speed signals
Maintaining signal integrity (SI) and preventing connectors from ruining high-speed signals requires careful attention to design details like impedance matching, minimizing reflections, reducing crosstalk, and ensuring proper terminations. It begins by defining the specific signal speed and bandwidth requirements and selecting the optimal connector. The definition of high-speed signals is relative to the application, and […]
How to select circular connector locking mechanisms
Circular connector locking mechanisms secure mated connections against vibration, shock, and accidental disconnection. Engineers select threaded, bayonet, push-pull, and breakaway mechanisms based on retention force, mating cycles, and application requirements. This article compares their operating principles and performance tradeoffs to guide connector selection. Operating principles of circular connector coupling mechanisms Threaded couplings use a coupling […]
How adhesives and sealants impact EV connector reliability and service life
Electric vehicle (EV) connectors must operate reliably despite intense vibration, thermal cycling, moisture exposure, and elevated temperatures. Adhesives and sealants applied to connector housings, cable entries, and termination points significantly improve sealing performance, vibration resistance, and mechanical stability. These materials can also introduce long-term failure modes driven by thermal expansion mismatch, chemical aging, and environmental […]
Derating connector current ratings for real-world PCB power designs
Many datasheet connector current ratings are based on test conditions that rarely reflect real-world printed circuit board (PCB) power designs. These values typically represent performance in free air at controlled ambient temperatures, with optimal copper distribution and without the thermal constraints imposed by dense board layouts, enclosures, or altitude. Engineers who apply these ratings directly […]
Be aware of connector mating-cycle limits
It’s easy to overlook vendor-specified mating cycle numbers for connectors and thus encounter problems over time. No, this title isn’t some kind of joke about how your connectors, if left alone at night, will magically spawn new mini-versions of themselves or miraculously grow new contact positions. Instead, it’s a serious issue that is easily overlooked […]
What connectors and interconnects are used in pacemakers and ICDs?
Pacemakers and implantable cardioverter defibrillators (ICDs) are small, battery-powered devices implanted under the skin to manage abnormal heart rhythms. Pacemakers deliver low-energy electrical impulses to treat bradycardia, while ICDs monitor life-threatening arrhythmias and deliver controlled, high-energy shocks. Despite their functional differences, both devices rely on specialized connectors and interconnects to ensure safe, long-term performance. This […]
Surge protection needs of automotive PoC systems
For automotive Power over Coax (PoC) systems, robust surge protection is required to safeguard sensitive electronics from a variety of damaging voltage transients present in the vehicle environment. The protection system must address hazards originating from the vehicle’s battery, electrostatic discharge (ESD) events, and other potential electrical faults. Robust surge protection is needed to protect […]
