Insulation Failure Analysis of Automotive Connectors
The insulation resistance refers to the resistance value presented by the surface or internal leakage current of the insulation part when a voltage is applied to the insulating part of the automotive connector. That is, insulation resistance (MΩ) = voltage applied to the insulation (V) / leakage current (μA). By inspecting the insulation resistance, it can be determined whether the insulation performance of the connector meets the requirements of the circuit design, or whether the insulation resistance meets the relevant technical conditions when subjected to environmental stresses such as high temperature and humidity.
The insulation resistance is a limiting factor for designing high-impedance circuits. Low insulation resistance means a large leakage current, which will disrupt the normal operation of the circuit. For example, the formation of a feedback loop, too much heat, and direct current electrolysis caused by a large leakage current will damage the insulation or deteriorate the electrical performance of the connector.
Insulation Material of the Automotive Connector
It is very important to choose the appropriate insulation material when designing electrical connectors. It often affects whether the insulation resistance of subsequent products can remain stable and qualified.
For example, a certain factory originally used insulation materials such as acetate fiberglass plastic and reinforced nylon, which contained polar genes and had high hygroscopicity. The insulation performance could meet the product requirements at room temperature but was not qualified in high temperature and humidity conditions.
Later, special engineering plastic PES (polyether sulfone) was used, and the insulation resistance of the product changed slightly after 200 ℃, 1000h, and 240h humid tests, still kept above 105MΩ without any abnormal changes.
Poor Sealing of Automotive Connectors
The electronic devices and wiring harnesses in the dry area are less affected by high temperature/high humidity, chemicals, and dust, while the wet area is just the opposite. If the sealing is poor, it may cause water ingress to electronic devices and wiring harnesses, causing internal circuit short-circuit/corrosion, and directly leading to malfunction, so the sealing of the connector joint of the wiring harness needs to be well protected.
Unreasonable Sealing Structure Design:
The compression of the sealing gasket is insufficient, and the sealing is no problem when the wiring harness is smoothly installed, but fails after bending.
Poor aging resistance and mechanical properties, long-term use will cause aging and cracking, resulting in sealing failure. It is recommended to choose a radial sealing structure during the sealing structure design.
Condensation: Due to the high air humidity inside the automotive connector during operation, water is condensed on the low-temperature surface due to temperature difference after stopping work, which leads to insulation failure, especially for connectors of heating components, such as drive motor connectors.
Siphon: The electronic components such as connectors mainly have two ways to get water. The first is that external liquid infiltrates into their interior by gravity, such as connectors without sealing rings. Or moisture enters from the internal connection points of wiring harnesses (such as unprotected welding points/pressure points/contact points). Here we emphasize the word "siphon", because generally electronic devices have a certain temperature during operation, and the internal air forms a certain pressure. When it stops working, the temperature drops and the internal pressure also decreases, which will form a pressure difference. If the sealing of the connector is poor, water vapor will enter the interior along the gap between the multiple copper wires, causing malfunction.
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本文由上山打老虎转载自Greenconn News，原文标题为:Insulation Failure Analysis of Automotive Connectors，本站所有转载文章系出于传递更多信息之目的，且明确注明来源，不希望被转载的媒体或个人可与我们联系，我们将立即进行删除处理。
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IMS（亿迈通讯）SMBA®（FAKRA）射频同轴连接器选型指南
IMS Connector Systems SMBA® connectors Applications SMBA® connectors Benefits SMBA® connectors Coding SMBA® connectors Technical specifications SMBA® Products Tools Assembly instructions
IMS CONNECTOR SYSTEMS - CONNECTORS,CABLE MOUNT ANGLE JACK,射频同轴连接器,插入件,手动压接工具,SMBA® CONNECTORS,CABLE MOUNT PLUG,TWIN CABLE PLUG,PCB双角插头,COAXIAL RF CONNECTORS,PCB角插头,CABLE MOUNT BULKHEAD PLUG,TWIN CABLE MOUNT ANGLE JACK,SEMI-AUTOMATIC CRIMP TOOLS,PCB ANGLE PLUG,半自动压接工具,电缆安装隔板插头,SMA测试仪,TWIN CABLE JACK,堵头,双电缆插头,SMA TESTADATPER,电缆安装插孔,INSERTS,RF-COAXIAL CONNECTORS,电缆安装角千斤顶,同轴连接器,双电缆安装角千斤顶,PCB MOUNT PLUG,连接器,PCB TWIN ANGLE PLUG,HAND CRIMP TOOL,COAXIAL CONNECTORS,CABLE MOUNT JACK,同轴射频连接器,双电缆插孔,电缆安装插头,BULKHEAD PLUG,PCB安装插头,4860.SMBA.1X10.007,3400.SMBA.2X10.089,4102.SMBA.2X20.029,AGK-3803,4101.SMBA.1X10.029,4846.SMBA.1X10.009,AGK-4077,AGK-4078,4914.SMBA.1X10.009,3401.SMBA.1X10.019,AGK-3573-14,3786.SMBA.1X10.049,4100.SMBA.2X10.029,AGK-3573-13,3849.SMBA.1X10.009,AGK-3573-10,3401.SMBA.1X10.0X9,AGK-3573-11,AGK-3802,4802.SMBA.1X10.039,AGK-4015,AGK-3762,AGK-3763,AGK-4016,4728.SMBA.1X10.009,3402.SMBA.1X10.029,4662.SMBA.1X10.009,4102.SMBA.2X20.039,4369.SMBA.1X10.009,4654.SMBA.1X10.049,4101.SMBA.1X10.039,AGK-4044,AGK-4045,4855.SMBA.1X10.007,AGK-4046,4100.SMBA.2X10.039,AGK-4086,AGK-4087,3401.SMBA.1X10.089,3403.SMBA.1X10.049,AGK-2365,3402.SMBA.1X10.019,4802.SMBA.1X10.029,3401.SMBA.1X10.049,3402.SMBA.1X10.039,DIGITAL RADIO,气压控制,事故数据分析,DISTANCE CONTROL,ENGINE MANAGEMENT SYSTEM,AIR PRESSURE CONTROL,ANALOG RADIO,TV/VIDEO-DISPLAYS,REMOTE CONTROL KEYLESS ENTRY,GPS ANTENNA,放大器,配电箱,ANALOG/DIGITAL RADIO,电视/视频显示器,ANTENNA,VIDEO-DISPLAYS,无源天线,TV-DISPLAYS,NAVIGATION SYSTEM,遥控无钥匙进入,汽车应用,AMPLIFIER,移动电话,辅助加热,CELLULAR PHONE,AUTOMOTIVE APPLICATIONS,AUXILIARY HEATING,模拟/数字无线电,DISTRIBUTOR BOX,发动机管理系统,ACCIDENT DATA ANALYSIS,导航系统,AUTOMOTIVE,天线,距离控制
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可定制连接器单PIN电流最大不超过10A；环境温度：-45度~+125度；寿命/拔插次数：不超过5000次。
最小起订量： 5000 提交需求>
可定制排针排母间距：0.8~2.54mm，排数：1~3，电流：最大不超过10A；环境温度：-45度~+125度；寿命/拔插次数：不超过5000次。
最小起订量： 5000 提交需求>
授权代理品牌：集成电路
授权代理品牌：分立元件
授权代理品牌：接插件及结构件
授权代理品牌：部件、组件及配件
授权代理品牌：电源及模块
授权代理品牌：电子材料
授权代理品牌：仪器仪表及测试配组件
授权代理品牌：电工工具及材料
授权代理品牌：机械电子元件
授权代理品牌：加工与定制
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