Electronic connectors are indispensable basic components in electronic devices, responsible for the key tasks of transmitting electrical energy, signals, and data. They are widely used in consumer electronics, industrial, automotive, communication, and other fields.

1. Definition of Electronic Connectors

An electronic connector is an electromechanical component used to connect electronic components and devices. It establishes temporary or permanent electrical connections to transmit current, signals, or data, while also providing mechanical fixation and environmental protection.

2. Common Classification Methods

By Function and Application

• Power Connectors: Transmit large currents and voltages, such as DC power sockets (laptop adapters), industrial/aerospace plugs (for harsh aerospace environments), and electric vehicle charging interfaces (CCS/CHAdeMO/GB/T, supporting high-power fast charging).
• Signal Connectors: Transmit low-current/low-voltage analog or digital signals, such as BNC (for video surveillance RF testing), SMA (for microwave communication high-frequency signals), and FPC/FFC (for internal screen/camera connections in mobile phones).
• Data Connectors: Transmit high-speed digital data or audio-visual signals, such as USB-C (multi-function integrated, supporting USB4/Thunderbolt), HDMI (4K/8K video transmission), and RJ45 (Ethernet network connections).
• Fiber Optic Connectors: Use optical fibers to transmit optical signals, enabling ultra-high-speed, long-distance, and anti-electromagnetic interference transmission, such as LC (for high-density cabling in data centers), SC (for FTTH fiber-to-the-home), and MTP/MPO (core components of 400G high-speed links).

By Structural Form and Connection Method

• Board-to-Board Connectors: Directly connect two printed circuit boards (PCBs), such as memory slots (DIMM) and mobile phone motherboard stacking connections (saving space and supporting high-speed signals).
• Wire-to-Board Connectors: Connect wires or cables to PCBs, such as pin headers/socket headers (for development board prototype design) and FFC/FPC connectors (for compact internal connections in consumer electronics).
• Wire-to-Wire Connectors: Connect two or more wires/cables, such as the connectors at both ends of USB data cables and automotive wiring harness connectors (IP6K9K waterproof, high-temperature and chemical corrosion resistant).
• Plug-in Connectors: Facilitate multiple insertions and extractions, such as RJ45 (for network debugging) and USB-C (reversible plug, integrating charging/data/audio-visual functions).
• Latching/Threaded Fixed Connectors: Provide secure connections via mechanical locking, such as D-Sub (screw-fixed for VGA interfaces) and M8/M12 circular connectors (for industrial automation, anti-vibration and impact).

By Application Field

• Consumer Electronics: Mobile phone USB-C/Lightning interfaces, tablet magnetic interfaces, and 3.5mm headphone jacks.
• Industrial: Connections between PLCs and sensors (resistant to harsh environments), internal signal transmission in industrial control equipment, and high-voltage/high-current connections in power equipment.
• Automotive: In-vehicle electronic systems (waterproof and dustproof), connections for high-temperature and vibration components in engine compartments, and charging interfaces (compatible with charging piles, supporting 800V high-voltage platform liquid-cooled design).
• Communication: Base station antenna connections (high-frequency signal shielding), fiber optic communication (low-loss optical signals), and internal board-to-board/wire-to-board connections in network equipment.

3. Main Functions

• Electrical Connection: Establishes a low-resistance path to ensure stable transmission of current or signals (low contact resistance, high insulation resistance).
• Signal Integrity: Ensures no signal distortion during transmission (e.g., impedance matching, anti-interference design).
• Mechanical Fixation: Provides reliable physical connections to resist external forces such as vibration and impact (moderate insertion/extraction force, high mechanical strength).
• Environmental Protection: Some connectors use sealed designs to be waterproof, dustproof, and corrosion-resistant (e.g., for automotive engine compartments and outdoor equipment).

The core function of connectors is to establish stable electrical connections while providing necessary mechanical support and environmental protection. High-quality connectors not only ensure signal transmission quality but also operate stably for a long time in harsh environments. Electrical connection performance is typically measured by parameters such as contact resistance, insulation resistance, and voltage withstand strength. High-quality connectors usually have contact resistance at the milliohm level and insulation resistance up to hundreds of megaohms or more, ensuring the stability and safety of signal transmission.

4. Typical Application Scenarios

• Consumer Electronics: Internal and external connections of mobile phones and computers (charging, data transmission), e.g., USB-C integrates charging, data, and audio-visual functions, supporting fast charging and high-definition display.
• Industrial Automation: Connect PLCs, sensors, and actuators to transmit control signals, requiring high reliability and resistance to harsh environments (e.g., M8/M12 connectors for industrial sensor-driver connections).
• Automotive Electronics: Connections for in-vehicle entertainment systems, sensors, and control units, adapted to high-temperature and vibration environments, e.g., 800V high-voltage platform charging connectors (liquid-cooled design, supporting 600A high current).
• Communication: 5G base station antenna connections (high-frequency signal transmission, strong shielding capability), data center fiber optic interconnection (MTP/MPO supporting 400G high-speed links), and home network RJ45 connections (Gigabit/10-Gigabit Ethernet).
• Aerospace: Power and signal transmission for aerospace equipment, e.g., industrial/aerospace plugs (complying with MIL-DTL-38999 standards), high-temperature and vibration resistant to ensure stable equipment operation.

Each field’s application imposes specific requirements on connectors. Connectors in consumer electronics emphasize miniaturization and multi-function integration; industrial connectors require durability and reliability; automotive connectors need to balance high-temperature vibration resistance and safety; communication connectors pursue high speed and stability; and aerospace connectors have extremely high reliability standards.

Connector technology development closely follows industry trends. For example, with the popularization of electric vehicles, charging connectors are continuously upgraded to support higher voltages and larger currents; with the promotion of 5G communication, high-frequency connector technology continues to innovate to meet millimeter-wave transmission needs; with the expansion of data centers, high-density fiber optic connectors have become key infrastructure.

Modern connector design needs to balance multiple requirements, including electrical performance, mechanical reliability, environmental adaptability, cost control, and manufacturing processes. Designers usually need to find the optimal balance among these factors to meet the needs of specific applications.