What Are The Defects Of The Power Distribution Contacts In Heavy-duty Connectors?

The information provided is that the volume resistance of the heavy duty crimp connectors contact needs to be significantly reduced. The reason is Joule heating, which is more pronounced at high currents and drives many design and material decisions for the power contacts and the heavy duty waterproof electrical connectors.

The resistance depends on the conductivity and geometry of the contact spring components. Increasing the cross-sectional area of ​​the heavy duty 2 pin connector contact reduces contact resistance, which is why high-current contacts tend to be larger than signal contacts. For the same reason, the conductor for terminating the contact will naturally be larger. This increase in size is a limitation of the special high-current heavy duty connector 16 pin contacts.

Furthermore, the permanent connection resistance is reduced due to the increased contact, conductor size, and contact area of ​​the heavy duty connector 5 pin contact. However, it is important to ensure that the heavy duty connector 6 pin contact itself is sized appropriately for the conductor. If the contact is used for a range of wire or bus sizes, the heavy duty electrical contacts must be able to carry the current of the largest conductor size within that range. However, the termination method of the heavy duty industrial connector may also be more problematic because the size of the contacts and conductors increases and higher termination forces are required, such as crimp connections or bolt assemblies, which is also a limitation of dedicated heavy-duty connector contacts.