Technology Update
By Fred Besnoff
In a large city hospital, a cutting-edge operation begins. A male patient in his mid-forties, blind since birth, is anesthetized and a small hole is drilled into the mastoid bone of his skull. A micro-miniature connector is mounted into the hole that will, in time, allow him to view objects in the form of black and white shadows for the first time.
In the near future, the bone will heal itself around the connector, sealing it in place. The fine wires, or leads, from this connector are installed into the optic area of the brain and tied in through an amplification device. The mating connector, attached to another device, obtains and transmits images to the optic portion of the brain through electrical impulses.
No, this is not a copy of the Journal of the American Medical Association. Similar procedures are being conducted with increasing success in such fields as aerospace, telecommunications, fiber optics, and audio and video. This is all because of one technology advancement: connector miniaturization.
Density requirements are one of the factors driving the continuing "micro-modularization" of connector design. NASA operations, from the Space Station Program to the launching of mini-satellites, are all dictated by weight sensitivity. Whenever possible, space-bound electronics must be multifunctional but with size kept to a minimum. These traveling electronics carry out such functions as examining infrared light and gamma radiation; visually analyzing topography, air and mineral samples; and transmitting data back to Earth. To support these tasks, circuitry is needed that requires higher interconnection capabilities housed in a smaller and denser area.
Audio and video broadcast engineers are challenged by the requirements of digital transmission, flat liquid crystal display (LCD) and projection screens, and faster data rate transmission. As studio space decreases, electronic devices and equipment must also decrease in size. The redirection of signals through patch panels (patch fields), which in many cases incorporates the use of these patches through "TB" or 0.25" jacks in panels 11/2U to 2U high, are being converted to "TT" or bantam jacks in panels 1U high. As a result, amplifiers, camera equipment and studio electronic modules are being constructed in smaller packages through the use of surface-mount technology, smaller components and again, smaller connectors.
Connector miniaturization has allowed engineers to overcome the challenges of directing signals from one piece of electronic equipment or modules to another under limited space conditions. As this technology continues to advance, the potential applications are limited only by imagination and innovation.
FRED BESNOFF is Product Applications Manager, Neutrik USA, 195 Lehigh Ave., Lakewood, NJ 08701; (732) 901-9488; Fax: (732) 901-9608; Web site: www.neutrikusa.com.
Stereo Plugs
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These 3.5 mm Stereo Plugs are suitable for applications requiring miniature connections, such as for headsets and wireless microphones. The plugs feature a heavy-duty cable clamp and a plastic insulator, which prevents contact between the bare wires and metal shell. The plugs have a dielectric strength of 500 Vrms, a temperature range of -10° to 70°C, and a contact resistance of <10 mW. Neutrik USA, Lakewood, N.J.
BNC Jack
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This 75 W BNC Separable Jack is for interconnecting mother- and daughterboards. The assembly is suitable for launching high-frequency signals directly from the edge of a PCB through the motherboard into a coaxial cable. The two-piece design consists of an edge-launch connector mounted to the daughterboard and a BNC "ground shell" mounted over a hole in the motherboard. A single edge-launch connector can be mated and unmated through the hole. Trompeter Electronics, Westlake Village, Calif.
EMI-shielded Connectors
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TM11 Series EMI-shielded Modular Connectors have a one-piece construction of the plug shell and clamp that provides EMI protection for ISDN applications. The jack shielding is said to easily engage and locks first upon mating, reportedly to protect equipment circuitry. The metal shell offers ESD protection and a plastic cover is provided for added strain relief. The shielded plug is available in six- or eight-positions. Hirose Electric (U.S.A.) Inc., Simi Valley, Calif.
Modular Jacks
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These 2 X 8 Stacked Modular Jacks have an offset design for midplane PCB mounting. They are suitable for networking equipment such as hubs, routers and switches. Network applications include Gigabit Ethernet, Fast Ethernet and 10Base-T. They provide 16 modular Category 5 jacks configured in a small footprint, and are available with or without LED indicators. AMP, a part of Tyco Electronics Corp., Harrisburg, Pa.
PCB Jack
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The Bantam PCB Jack #PC-1088-HT can be attached to the PCB with the reflow oven process. It is made from liquid crystal polymers, and withstands reflow oven temperatures up to 250°C. Using the reflow process is said to provide a more stable and cost-effective connection compared to wave or hand soldering. The jack monitor and test port reportedly provide access for splitting and isolation of the DS1 signal. ADC Telecommunications Inc., Minneapolis, Minn.
Miniature Phone Jack
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The CTP-J-2504 Series 2.5 mm Jack is surface-mount configurable, and comes taped-and-reeled or bulk-packed. The jack accepts either a 2.5 mm plug that has the four positions in a row or a plug that has three contacts on the fourth position. The jack is rated at 10K life cycles and features switched contacts for the tip and ring, which allow the application to switch the output from internal to external. Mating moldable plugs and molded cable assemblies are available. Connect-Tech Products Inc., Carson City, Nev.
Connectors
QuickPort Snap-in Category 5, GigaMax 5e, GigaMax 5E Plus and eXtreme Category 6 Connectors feature color-coded wiring labels with T568A and T568B wiring patterns, for reported dual flexibility in a single connector and accurate termination of station wiring. The connectors are available in 13 colors, and are said to meet or exceed industry standards. All category-rated connectors are compliant with TIA-568A requirements. Leviton Voice and Data, Bothell, Wash.
Modular Jacks
These Modular Jacks (Modjacks) are designed to help maintain signal integrity while reducing costs. The design uses lightpipes and customer-supplied surface-mount LEDs, which in combination reportedly reduce EMI/RFI (antenna effect) noise by 50 percent compared to modular jacks with integral LEDs. These inverted, right-angle jacks are available in shielded and nonshielded versions for RJ-11 and RJ-45 configurations, and in through-hole styles for wave soldering or high-temperature reflow soldering. Molex Inc., Lisle, Ill.
Audio Jacks
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Surface-mount Audio Jacks are designed for interface with audio equipment including computer speakers, headphones, cell phones and sound cards. They accept 2.5 and 3.5 mm plugs for mono or stereo applications, and are manufactured using a polyamide housing, UL 94V-0-rated; 0.012 brass gold-plated ground terminals; 0.008 phosphor bronze gold-plated spring contacts; and 0.012 brass gold-plated shunt terminals. Keystone Electronics Corp., Astoria, N.Y.
Audio Jacks and Plugs
These Audio Jacks and Plugs are available in a variety of sizes, shapes and angles, and platings. Jack options include straight or right-angle housings, mono or stereo, plastic or Bakelite handles, RCA pins, waterproofing, dual stacking, and internal switching. Male and female plugs are available for assembly or molding, or as premolded cable assemblies. Plug options include end terminations, durability-enhancing strain reliefs, and 30 to 18 AWG, single or multiwire. Shogyo International Corp., Plainview, N.Y.
Test and Tip Jacks
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These Test and Tip Jacks are offered in a range of mounting styles, insulators, contact materials and finishes for standard and custom applications. They are said to meet rigorous operating test requirements in a variety of environmental conditions. They also meet DIN 41616, IEC #S203 and AT&T specification standards. Eby Co., Philadelphia, Pa.
Plugs and Receptacles
The DSN6 Series of switch-rated plugs and receptacles consists of compact 20, 30 and 60 A watertight devices that feature silver/nickel pressure contacts. They carry a NEMA 4X rating for watertightness, and are UL-listed under 98/508/1682. They are also rated for a maximum of 20 HP at 480 VAC, for three-phase, and switch-rated to 600 VAC. The devices are available in up to four-pole/five-wire configurations, and the 30 and 60 A devices are also available with two pilot contacts/auxiliary contacts. Meltric Corp., Franklin, Wis.
Stereo Jacks
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Shielded 3.5 mm Stereo Jacks are designed for audio applications or electronic equipment using industry-standard stereo jacks. The stacked configuration reportedly saves PCB space, while the built-in shielding preserves high signal-to-noise ratios. These connectors are UL-recognized and CSA-certified. The products include three to nine contacts, all of which carry a 1 A current rating. Adam Technologies Inc., a Methode Electronics Inc. company, Union, N.J.
Modular Jacks
GIS Series Modular Jacks are designed for high-speed data applications. They are available with different filtering packages to accommodate the various chipsets commonly found in 10/100Base-T applications. With the required transformers, chokes, capacitors and termination resistors installed within the connector, the jacks are said to offer reliability and electrical performance over traditional options using separate components. Several designs including high-temperature versions are available. Kycon Inc., San Jose, Calif.
Jack Module
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The Mini-Com TX-5 Jack Module features the Giga-TX termination method that is said to speed installation and reduce conductor untwist to eliminate crosstalk variability. The design reportedly meets all requirements of the TIA/EIA Category 5 industry standards, and can be terminated without the use of a punchdown tool. The contacts are plated with 50 mm of gold and meet FCC Part 68 Subpart F. Panduit Corp., Tinley Park, Ill.
