Twist-Pin Concept Increases Miniature Connector Reliability

Sept. 30, 2002

Taking a 30-year-old connector contact concept one step further, Tyco Electronics' high-reliability microminiature connectors exceed certain Mil standards, suiting them for aerospace, defense, medical-equipment, and various instrumentation applications. Known as "twist pin," the concept involves obtaining as many points of contact possible within a connection interface.

The connector consists of a "bird-caged" stranded wire acting as the male component of the system and a precision gold-plated socket as the female element. Contacts can be spaced on centerlines as close as 0.05 in. The technology can be applied to many microminiature connector interfaces and can be used in high-density microminiature D connectors. It's also available in circular and rectangular connectors.

Wires are twisted into a helical shape, and the strands are bonded to form a tip. The tip is depressed, with the contact bulging in the center. The bulge makes contact with the inside of the socket (see the photo).

Unlike older twist-pin de-signs that use seven wire strands, Tyco uses nine for improved electrical performance. Tested in accordance with Mil-Std 1344 Method 5, test conditions IV and E, the twist-pin contacts showed no discontinuities for more than 1 µs. They also meet Mil specs for humidity, salt-spray, and fluid immersion.

Using a Microdot low-force socket, the nine-strand unit features a reduction in engagement force down to 100 grams, compared with the usual 200 to 400 grams needed for screwed machine contacts. The contacts are rated for a minimum of 500 mating cycles without any electrical performance degradation. They can handle wire sizes from 24 to 30 AWG and up to 3 A of current.

Contact Tyco at (800) 522-6752 or [email protected].

About the Author

Roger Allan

Roger Allan is an electronics journalism veteran, and served as Electronic Design's Executive Editor for 15 of those years. He has covered just about every technology beat from semiconductors, components, packaging and power devices, to communications, test and measurement, automotive electronics, robotics, medical electronics, military electronics, robotics, and industrial electronics. His specialties include MEMS and nanoelectronics technologies. He is a contributor to the McGraw Hill Annual Encyclopedia of Science and Technology. He is also a Life Senior Member of the IEEE and holds a BSEE from New York University's School of Engineering and Science. Roger has worked for major electronics magazines besides Electronic Design, including the IEEE Spectrum, Electronics, EDN, Electronic Products, and the British New Scientist. He also has working experience in the electronics industry as a design engineer in filters, power supplies and control systems.

After his retirement from Electronic Design Magazine, He has been extensively contributing articles for Penton’s Electronic Design, Power Electronics Technology, Energy Efficiency and Technology (EE&T) and Microwaves RF Magazine, covering all of the aforementioned electronics segments as well as energy efficiency, harvesting and related technologies. He has also contributed articles to other electronics technology magazines worldwide.

He is a “jack of all trades and a master in leading-edge technologies” like MEMS, nanolectronics, autonomous vehicles, artificial intelligence, military electronics, biometrics, implantable medical devices, and energy harvesting and related technologies.