Molex, a pioneering leader in connector technology, has recently released a comprehensive report . Entitled "Breaking Boundaries: Combining Ruggedization and Miniaturization in Connector Design," the report focuses on design trends, trade-offs, and enabling technologies that remove barriers and shape the future of electronic products.

Carrieanne Piccard, Vice President and General Manager of Molex Connected Mobility Solutions, commented, "With the increasing demand for electronics in new automotive platforms, there is a growing market need for smaller, more rugged interconnect products that can operate reliably in extremely harsh environments. Therefore, making connectors more rugged and compact has become a core design principle, requiring a holistic approach throughout the component lifecycle to achieve optimal product reliability,

Connectors are critical drivers of advancement across various fields

In this industry report, Molex defines miniature connectors as those with terminal pitches not exceeding 2.54 millimeters, and its robustness is reflected in its ability to withstand the harshest environments and mechanical stresses. This trend of merging miniaturization with ruggedness is fueling significant innovation, particularly in the automotive sector for electric vehicles (EVs) and zonal architectures. Currently, this trend is permeating other industries, including consumer electronics (e.g., fitness trackers, smartwatches, and smart home devices), industrial automation (e.g., industrial robots, touchscreens, and sensors), and medical devices (e.g., endoscopes, insulin pumps, and wearable health monitors).

Compact and durable connectors are increasingly favored in smart agriculture and other application domains. Vertical farming systems equipped with densely packed sensors, lighting fixtures require space-saving connectors capable of operating reliably in humid environments. Similarly, compact, lightweight, and robust connectors used in agricultural drones or "flying tractors" need protection against extreme temperatures, excessive vibrations, as well as moisture, dust, and corrosive chemicals.

Break through design boundaries

Molex's latest report examines key strategies for overcoming significant design and manufacturing challenges to facilitate the development of smaller, lighter, and more reliable connectors. Materials such as aluminum alloys, specialized high-strength steels, and high-performance polymers offer excellent durability and lightweight structures. However, processing these materials into connectors with complex geometries typically requires specialized techniques including micro-molding, high-precision machining, laser welding, and selective plating.

Furthermore, employing high-density terminal layouts can increase contact density to accommodate smaller device sizes, necessitating precise manufacturing and assembly. This approach may introduce risks such as crosstalk and thermal issues. To address these challenges, engineers can adopt advanced signal routing techniques, shielding isolation measures, and thermal management strategies such as heat sinks or thermal vias.Molex's DuraClik connector housings, manufactured from high-temperature PBT materials, feature robust terminal retention mechanisms, capable of withstanding harsh automotive environments.

Multi-function terminals (MFT) integrate various functions—power, signal connection, and mechanical features like locking mechanisms—into a single compact connector, marking a significant leap in miniaturized connector technology.Molex's latest report discusses key environmental factors affecting component reliability and proposes strategies and solutions to ensure optimal connector performance under extreme conditions. Stress relief features coupled with terminal design enhance connector performance, maintaining stability during continuous vibration, impact, and frequent mating cycles.

Engineers at Molex's global reliability labs rigorously simulate real-world conditions including vibration, temperature cycling, and exposure to aggressive chemicals. The Micro-Lock Plus connector employs a positive locking mechanism to ensure secure connections and prevent accidental disengagement under strong vibration conditions.Its metal solder tabs provide additional stress relief for solder joints, enhancing resistance to mechanical stress and vibration.

Even minimal water droplets or dust can lead to circuit corrosion and short circuits, resulting in equipment failures. Effective protection measures are therefore critical. Molex's Squba connectors, featuring IP68-rated sealing technology, sustain uninterrupted operation up to 5 feet underwater for 30 minutes, unaffected by water. These intricately designed connectors optimize power transmission pathways in compact and durable forms.

As equipment sizes continue to shrink and functionalities increase, Molex engineers are continually pushing the limits of miniaturization and ruggedization in design. Their efforts aim to address real-world business challenges and exceed customer expectations.Their innovations not only meet but exceed real-world business challenges, setting new benchmarks in connector technology.