The introduction of cube satellites (CubeSats) in the late 1990s and early 2000s sparked a driving effort to reduce the overall size and weight of the craft while improving capability. Gone are the days of single, large, ultra-expensive satellites. Constellations of these nanosatellites that utilize small, ruggedized connectors are being launched regularly. Requirements for CubeSats may have a weight budget for plated plastic connectors only. Where EMI may be less of an obstacle, connector assemblies without metal housings keep the form factor to an absolute minimum. In other space applications, the need for an aluminum or stainless housing with gold plating is a necessity for shielding cosmic radiation.
exposure. Recent technology also allows for plating of plastics to enhance electrical properties, with overall weight of the connector being relatively unaffected by the addition of nickel plating. More ruggedized lightweight connectors with metal shells are fabricated using aluminum alloys and plated for additional corrosion protection. This allows the protection and durability of metal without the risk associated with a “plastic” only connector. Small lightweight ruggedized connectors have physics working to their advantage. Form factors, weight, and engineered materials combine to create solutions that are nearly insusceptible to damage from shock and vibration that occurs during launch. POWER Power needs, followed by quantity of signals, are typically addressed first when designing miniature ruggedized connectors. Power should be considered in terms of voltage and current. In most cases digital signaling working voltage is low, and generally not an issue. Power demand may dictate a larger wire gauge than the 26 and 30AWG found in micro- and nano-sized offerings. These deliver 3 A or 1 A of current respectively. Designers sticking with a traditional connector may end up spreading power across multiple contacts, which can ultimately affect the overall size and weight of the solution. Mentioned earlier, hybrid solutions are an option for designs to provide specific power contacts and additional signal lines in a reduced size to keep the overall form factor at a minimum. Unmanned
Latching PPS connectors
SWaP has become a priority in many applications. In recent years, a number of connector manufacturers have started offering different form factors without a metal shell in alternate configurations to save size and weight while delivering much needed power. In these cases, weight is decreased by eliminating the metal housing, and using advanced polymers able to withstand the environment. Materials such as polyimide, PEEK, and Ultem, to name a few, are used in environments where resistance to chemicals and temperature is needed for extended
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