Connector Insulating Components
Overview
Precision-engineered dielectric components designed to maintain electrical isolation, withstand mechanical stress, and prevent flashover in high-density and high-voltage connector assemblies.
Connector insulating components serve as the dielectric core and structural housing support within multi-pin electrical and electronic connectors. They prevent current leakage between adjacent contacts, isolate live circuits from external metal housings, and maintain pin alignment under continuous mechanical vibration.
Engineered for demanding industrial, automotive, and energy environments, our components are manufactured through precision injection molding and CNC machining to achieve tight dimensional tolerances and strict electrical performance benchmarks.
Specifications
|
Parameter |
Technical Standard / Range |
|
Primary Materials |
PBT, LCP, PA66, PPS, PTFE, PEEK, Silicone |
|
Dielectric Strength |
20 kV/mm to 40 kV/mm (ASTM D149) |
|
Comparative Tracking Index (CTI) |
CTI 600V+ (PLC 0) |
|
Operating Temperature Range |
-40°C to +260°C (polymer dependent) |
|
Flammability Rating |
UL94 V-0 |
|
Dimensional Tolerance |
Up to ±0.01 mm (micromolding capability) |
|
Regulatory Compliance |
RoHS, REACH, UL Listed, IATF 16949 standards |
Features
High Dielectric Withstand Voltage: Prevents electrical breakdown and arc discharge under high-voltage loads.
Low Moisture Absorption: Preserves stable electrical resistivity and prevents dimensional swelling in humid conditions.
Thermal Dimensional Stability: Resists warping and creep during high-temperature reflow soldering or continuous high-current operation.
Tight Pitch Capability: Thin-wall molding down to 0.2 mm wall thickness for micro-connector architectures.
Chemical & Fluid Resistance: Withstands exposure to aggressive automotive fluids, cleaning solvents, and industrial lubricants.
Materials & Manufacturing
Material Selection
LCP (Liquid Crystal Polymer): Selected for ultra-thin walls, high heat deflection, and SMT-compatible connector designs.
PBT (Polybutylene Terephthalate): Provides a balanced combination of mechanical strength, electrical insulation, and cost-efficiency for industrial connectors.
PPS (Polyphenylene Sulfide): Delivers extreme chemical resistance and continuous thermal endurance up to 240°C.
Manufacturing Process
Precision Injection Molding: Executed on closed-loop electric injection molding machines (50T–250T) with real-time cavity pressure and temperature monitoring.
Tooling Capability: In-house mold design and high-precision CNC tool fabrication utilizing Mikron and AgieCharmilles EDM equipment, achieving mold tolerances within ±0.005 mm.
Post-Processing: Automated flash removal and controlled thermal annealing to eliminate internal mechanical stress.
Applications
Electric Vehicles (EV): High-voltage battery pack connectors, On-Board Chargers (OBC), and charging inlet assemblies.
Industrial Automation: Servo motor connectors, heavy-duty industrial interfaces (M12/M8), and modular PLC terminal blocks.
Renewable Energy: Solar inverter DC connectors and wind turbine control signal harnesses.
Medical Devices: Diagnostic equipment interconnects requiring sterilizable insulation properties.
Customization
Build-to-Print (B2P): Production executed strictly to customer CAD files (STEP, IGES, SolidWorks) and 2D technical drawings.
Polymer Compounding: Tailored filler integration (glass fiber reinforcement, mineral filling, anti-static additives) to hit target mechanical or thermal metrics.
Insert Molding: Overmolding insulation directly around stamped metal pins or threaded brass inserts in a single operation.
Prototyping: Rapid CNC machining or 3D-printed functional samples delivered prior to hard steel tooling investment.
QC
Manufacturing and quality assurance operations adhere strictly to IATF 16949 and ISO 9001 frameworks.
Dimensional Verification: Key dimensions inspected via Keyence Optical Comparators and 3D CMM (Coordinate Measuring Machines).
Electrical Screening: 100% batch testing for dielectric withstanding voltage (Hi-Pot test) and insulation resistance where specified.
Material Traceability: Raw material lot numbers logged for every production run, backed by supplied Material Test Reports (MTR / CoA).
Process Control: Statistical Process Control (SPC) charts utilized to monitor shot-to-shot consistency and prevent drift.
FAQ
Q: What is the minimum wall thickness you can achieve for miniature connector inserts?
A: We routinely mold wall thicknesses down to 0.2 mm using high-flow LCP grades, preserving structural integrity without sink marks.
Q: Can you supply UL94 V-0 certified materials with specific CTI ratings?
A: Yes. All stock engineering polymers (PBT, LCP, PPS, PA66) carry UL94 V-0 certification, with CTI performance ranging from PLC 2 up to PLC 0 (600V+).
Q: What is the standard tooling lead time for custom molded components?
A: Tooling design and fabrication generally require 3 to 4 weeks, followed by 1 week for T1 sample submission and full dimensional report generation.
Q: Do you support PPAP documentation for automotive programs?
A: Yes, Level 1 through Level 3 PPAP documentation-including Dimensional Results, Material Certificates, and Process Flow Diagrams-is available upon request.
RFQ
To initiate a formal technical evaluation and quotation within 24 hours, please supply the following parameters:
Engineering Drawings: STEP/IGES files with explicit tolerance callouts and material specifications.
Volume Projections: Estimated Annual Volume (EAU) and target delivery schedules.
Performance Criteria: Operating voltage, working temperature limits, and target CTI or UL ratings.
Secondary Specifications: Post-molding testing requirements, custom packaging, or compliance demands (RoHS, REACH, PPAP).
Hot Tags: connector insulating components, China connector insulating components manufacturers, suppliers, factory
Send Inquiry
