Article Index

Materials Electrical connectors essentially consist of two classes of materials: conductors and insulators. Properties important to conductor materials are conductivity, mechanical strength, formability, and resilience. Insulators must have a high electrical resistance, withstand high temperatures, and be easy to manufacture for a precise fit.

Electrodes in connectors are usually made of copper alloys, due to their good conductivity and malleability. Alternatives include brass, phosphor bronze, and beryllium copper. The base electrode metal is often coated with another inert metal such as gold, nickel, or tin. This increases the electrical conductivity and durability. For example, copper alloys have favorable mechanical properties for electrodes, but are hard to solder and prone to corrosion. Thus, copper pins are usually coated with gold to alleviate these pitfalls, especially for analog signals and high reliability applications.

Contact carriers which hold the parts of a connector together are usually made of plastic due to its insulating properties, and housings or backshells can be made of molded plastic or metal.