Power is the foundation of all electronics. Without stable power, there is no stable device, and connectors play a heavy role in power transmission. When purchasing connectors, in addition to paying attention to the stability and safety of connectors during power transmission, the convenience and design flexibility connectors bring to equipment manufacturing and assembly must also be considered. This article outlines some features and characteristics of the Mini-FiT MAX power connectors from Molex – a supplier of one of the widest range of power connectors, globally.
Perfect FiTs For Design Flexibility
Many original equipment manufacturers (OEMs) require power connectors that support a high degree of design flexibility. Targeting these needs, Molex’s FiT family of power connectors offer design selections of colored polarized housings with isolated terminals, Terminal Position Assurance (TPA) features, positive locks and tangless terminals.
The mechanical keyed feature of Molex’s FiT series of power connectors allows same circuit, and multiple connector use with virtually no chance of cross-mating. They support reflow oven capabilities, making soldering easy. Terminals in Molex’s FiT family connectors feature multiple points of contact, so if one part of the contact degrades or becomes blocked by debris, the other points of contact continue to carry the load. As a result, terminals provide high current-carrying capability whilst ensuring electrical and operational stability.
Molex’s FiT family of connectors feature positive locking latches designed with an audible ‘click’ to give operators feedback that the parts have been securely mated. In addition, with a proprietary scoop-proof design (prevents accidental pin bending and damage during mating operations), contacts are protected until the mating connectors are properly aligned. Therefore, damage related to aggressive unaligned mating and unmating are virtually eliminated. Molex’s FiT family connectors feature fully isolated contacts that inhibit arcing between contacts, enabling use at higher voltages; as well as better electrical isolation between adjacent contacts. By isolating contacts, contact damage and shorting risks due to debris contamination can be minimized during handling and shipping.
Molex’s FiT family of interconnects include Nano-FiT, Micro-FiT, Micro-FiT+, Ultra-FiT, Mini-FiT and Mini-FiT Sigma Sealed solutions and Mega-FiT Power Connectors that address a variety of power applications.
The Family With a Rich Portfolio – Mini-FiT Power Connectors
For high-current applications, Molex’s Mini-FiT family power connectors support operating temperatures up to +125°C, and offers a double crimp tool, in board-to-board, wire-to-board, and wire-to-wire configurations. These provide a rich portfolio of products such as single-row and dual-row systems, Sigma systems (single-row and dual-row options), TPA2 systems (in single-row and dual-row options), high-current systems (single-row and dual-row options), Blind-Mate Interface (BMI) connector systems, Mini-FiT Versa color-coded designs (with glow-wire capability), Mini-FiT Max (single-row and dual-row options), with a host of accessories and cable assemblies to support the most diverse application needs.
Various OEMs require high-current, high-density power connectors for some of their most complex application designs. To meet these needs, the Mini-FiT Jr., Mini-FiT Plus, Mini-FiT Blind-Mate Interface (BMI), and Mini-FiT TPA2 connectors are available that offer polarized housings with isolated terminals, positive locks, and low-engagement force features. All versions of Mini-FiT Jr. and Mini-FiT Plus Connectors are compatible with each other, including Mini-FiT TPA2 and Mini-FiT BMI components, bringing flexibility to the toughest design challenges.
Customers with blind mate applications require connectors that make assembly easy, protect against mis-mating and potential contact terminal damage. Mini-FiT BMI Connectors allow misalignment and provide up to 2.54mm of float between mating surfaces for easy blind-mate connections. Furthermore, connector flanges help “gather” the mating receptacle for more accurate mating.
Incorrectly assembled connectors can lead to terminal back-outs causing end-product failure. The impact of terminal back-outs can result in liability costs to manufacturers and electrical risks to users. Mini-FiT TPA2 Connectors prevent end-product failure by offering Terminal Position Assurance (TPA) - a design feature that reduces terminal back-out by providing locking redundancy. The Mini-FiT TPA2 receptacles are backward-compatible with Mini-FiT Jr. Headers, eliminating the need for costly overhauls in PCB designs.
Choose Mini-FiT Max for ‘Medium-Power’ Type Power Applications
As designs and applications increasingly focus on power systems, engineers look for connectors that support medium (10.0A) to high (25.0A) level currents. The quality problems faced by many terminal manufacturers often relate directly to terminal back-outs in connectors. On the other hand, customers with blind-mate applications require connectors that reduce the chances of mismating, achieve shorter assembly time without the need for special tools. European electrical standards require connectors with glow-wire capable for operational and user safety.
To meet medium-power application needs, Molex launched its Mini-FiT Max medium-power connector solution. Mini-FiT Max wire-to-board connectors support 20.5A of current in a compact package with design advantages that include robust tangless terminals used with TPA-capable receptacle.
The Mini-FiT Max connector uses a 94/V-0 glow-wire combination resin that reduces the cost of materials and labor and allows customers to meet European standards for electrical requirements. Unlike the standard Mini-FiT connector, the Mini-FiT Max connector supports keying and polarization, helps prevent mis-mating, and has a slim profile design that saves PCB space while supporting end-to-end stackability. It provides more power per linear inch and per square millimeter than other medium-power power connectors. The Mini-FiT Max connector has four independent points of contacts and offers redundant secondary current paths for long-term performance and reliability.
Terminal Position Assurance (TPA) is a design feature that helps to ensure proper terminal alignment within the connector. This feature is vital for reliable electrical connection, and when used, translates to time- and money savings, whether in the home in consumer appliances, commercial vehicles, industrial automation or telecommunications and network systems. The Mini-FiT Max connector offers TPA locking that fully and properly seats crimp terminals within in the connector housing, with reduced terminal backouts ensuring safe, reliable operations.
Avoiding Damage Caused by Mis-alignment During Mating and Unmating
Tangless terminals can provide manufacturers and harness assembly teams with adequate protection for terminals during packaging and assembly insertion from damage caused by aggressive unaligned mating and unmating, and are often used in consumer, commercial vehicles, home appliances, industrial automation, and other applications. Molex's Mini-FiT Max connectors use tangless terminals to help ensure the safety of terminals during packing and shipping and provide highly robust terminal design and safety. The Mini-FiT Max connector also provides a single-row option with circuit sizes from 2 to 6.
The Mini-FiT Max connector supports 600V maximum voltage, 20.5A maximum current, 2MΩ contact resistance, < 5mA dielectric withstanding voltage, and 1000MΩ minimum insulation resistance. Its mechanism performance includes a housing contact retention force of 40.0N, a mating force of 6.0N, and a unmating force of 4.0N. In terms of durability, it can accept 20 cycles per minute.
The Mini-FiT Max connector has a housing utilizing a UL 94V-0/glow wire with a pitch of 4.20 mm, a wire diameter specification of 16-28 AWG (American Wire Gauge), Tin (Sn) contacts, with Tin (Sn) plating at the contact and solder tail area, and an underplating of nickel (Ni), enabling the connector to operate at temperatures of -40° to + 105°C. The connector is RoHS compliant and halogen-free for environmental sustainability.
Mini-FiT Max connectors can be used extensively in telecommunications/network products such as switches, servers, power supplies and distribution, network towers, as well as in industrial applications such as machinery, commercial equipment, commercial lighting, industrial HVAC systems. The product is an excellent choice for use in consumer appliances such as heaters and air conditioners, washing machines and dryers. In commercial vehicle applications, the connector can be used in power converters, unsealed electronic control modules, transportation trucks and more.
Conclusion
Power connectors are indispensable components in electronic products and are key building blocks in ensuring the long-term stability of equipment operation. Molex’s array of power connectors address the needs of a wide range of power applications, which, in addition to providing stability and safety to power connections, speed up equipment manufacturing, assembly efficiency, as well as easy user maintenance. Molex’s power connectors are available in standard and custom designs. Visit Molex's official website today to learn more about our wealth of power connectors that protect your application investments.