High Power and High Voltage Connectors and Contacts
Amphenol Aerospace has led the connector industry with Military and Aerospace Power Distribution Connector Solutions. Whether it was helping to power soldier shelter systems, military ground vehicles, commercial aircraft engines, or the latest space launch vehicles, Amphenol Aerospace has been at the forefront of design and development. As we move beyond the current Mil-Spec standards to more custom, high-power needs, our connector designs and solutions have continued to evolve as the demand for more power increases. See our Product Configurator for available drawings and 3D models.
The foundation of our newest High Power Products is the development of our High Power Contacts which allow for greater current carrying capacity, or amperage, and are able to withstand higher temperatures in the same sizes as current Mil-Spec style pin and socket contacts. Our Temper Grip Contacts which utilize a stainless steel napkin ring to prevent the beryllium copper tines from “relaxing” at higher temperatures and maintaining a greater area of true contact in all situations to decrease resistance, are rated for 220 amps and 200+ deg C for Size 0 contacts. Our RADSOK Socket Contacts utilize a stamped and formed flat grid, uniquely twisted into a hyperbolic geometry to provide robust, high-density contact, are rated 250 deg C for Size 0 contacts. Our new HCP (High Current Pin) Contacts, which are fully interchangeable with AS39029 pin contacts, use high conductivity alloys and precision machining to improve ampacity up to 20%.
These new contact technology developments allow us to greatly improve on Mil-Spec standard connectors, such as MIL-DTL-38999 Series III, MIL-DTL-5015, and MIL-DTL-22992, to design the next generation of High Power Connectors. The Matrix 38999 Series combines the best of 38999 Series III shells and 5015 Connectors insert assemblies with Temper Grip and RADSOK Socket Contacts to provide a much-improved power connector with greater EMI performance in a familiar connector package. The High Power 38999 and High Power 5015 Series also use Temper Grip and RADSOK contacts to give users up to 1000 amps current carrying capacity. Our MIL-DTL-22992 Connectors include the standard Mil-Spec versions, as well as Commercial Class L Connectors and QWLD Connectors. We also have a rectangular, rack and panel-style HVDC Connector for commercial aerospace power needs that can support up to 365 amps.
In order to provide solutions for all-electric power requirements on commercial aircraft and urban air mobility vehicles, or eVTOLs, we have developed the High Voltage 38999 Series. These connectors were developed as future power distribution architecture is moving toward higher voltages above what standard connectors are designed to accommodate. They are rated for up to 1200 VAC / 1500 VDC* to remain partial discharge free at 50,000 ft. Standard D38999 Series III shells are used and Dualok plugs are available for increased shock and vibration performance.