Amphenol
®
Low Mating Force
Rectangular Connectors
12-035-12
MIL-DTL-55302
BRUSH CONTACT
TECHNOLOGY
Amphenol
®
Bristle Brush Contact:
Multiple Strands of High Tensile Strength
Wires Bundled Together, Providing Superior
Electrical Connection with Low Mating Force
Amphenol
Aerospace
www.amphenol-aerospace.com
Visit our website and see the very broad range of cylindrical and
rectangular interconnection products from Amphenol Aerospace.
Amphenol’s Broad Family
of Low Mating Force
Interconnect Products
with Brush Contacts
Design Flexibility -
Combination of Brush
Contacts and Fiber
Optic Termini
The Bristle Brush contact has been
proven in military avionics pack-
ages and meets the requirements
of MIL-DTL-55302. It provides high
density in tighter spacing, low mat-
ing/unmating forces, proven durabil-
ity and long contact life. Applications
for Amphenol
®
Connectors with
Brush contacts include:
• Medical equipment
• IC chip testers
• Telecommunications
• Military and Commercial Aviation
• Military Ground Vehicles
• GPS systems
Combination of Brush
Contacts, Coax and
Power Contacts
Other Similar Rectangular
Connectors from Amphenol
For more information, see additional Amphenol
Rectangular Products at the end of this catalog.
High Density
HDB
3
and HSB
3
Series
Power Strip Connector
Series with cavities for
size 16 or 12 power
contacts (or size 16 or
12 coax contacts).
LRM (Line Replaceable Module)
Interconnects
Hybrid Custom
Connector with Brush
Contacts and
Power Contacts
Ruggedized
Brush Rack & Panel
Connectors
Docking Connectors -
The Brush Contact
offers high performance
where frequent docking
to charge and transfer
data is a necessity.
Ruggedized
VME64x Interconnects
High Speed LRM
Gigastak &
Digastak Inserts
Brush vs. Conventional Contacts
Brush Contact Innovation
• Multiple contact interfaces -
Strands of high tensile wire are
bundled together to form
brush-like contacts. By inter-
meshing two multi-strand wire
bundles, an electrical connection
is made.
• Provides redundant current
paths, 14-70 (points of contact)
per mated contact with a gas
tight junction
• Very smooth (low friction)
interface
Conventional Pin/Socket
• Machined surface finish on
both parts
• Higher friction and wear
• Limited number of contact sites
Brush Contacts
Conventional Pin and Socket
Crimp Contacts
Amphenol’s High Technology
Machining and Computer Driven
Centers for Connector and
Contact Production
Amphenol Aerospace, located in
upstate New York USA, has
diverse manufacturing capability
including state of the art CNC
machining, die-casting, molding,
impact and extruding, screw
machining and plating.
Also within this facility are com-
plete design engineering and
environmental test facilities.
High technology production centers
at the Amphenol home facility and
its satellite facilities create volume
runs that are cost effective and
High Technology Machine Center
meet on-time delivery demands.
Amphenol operates a Quality Sys-
tem that is third-party certified to
ISO-9001:2008 and AS9100.
For more information on Amphenol
Aerospace capabilities in Rectan-
gular products, or any other of the
wide range of connector products,
please contact us:
Amphenol Aerospace Operations
40-60 Delaware Avenue
Sidney, NY 13838-1395
Phone: 800-678-0141 or
607-563-5011
Brush Contact Machining
www.amphenol-aerospace.com
Bristle Brush Contacts
• High density in tighter spacing - a main concern for integrated electronics.
• A superior choice for board level interconnects.
Amphenol
®
B
3
Bristle
®
Brush
®
Contact
Advantages:
Table of Contents
Low Mating Force Rectangular Connectors with Brush Contacts
Features, Peformance, Materials . . . . . . . . . . . . . . 1
Selecting the Correct Mated Connection,
Four Body Styles . . . . . . . . . . . . . . . . . . . . . 2
How to Order
Military and Commercial . . . . . . . . . . . . . . . . . 3-5
Connector Row and Cavity Identification,
Contact Arrangements 2 Row . . . . . . . . . . . . . . . 6
Contact Arrangements 3 and 4 Row . . . . . . . . . . . . . 7
Mother Board Connector . . . . . . . . . . . . . . . . . 8-11
Daughter Board Connector . . . . . . . . . . . . . . . 12-15
Input/Output Connector . . . . . . . . . . . . . . . . 16-19
PC Connector . . . . . . . . . . . . . . . . . . . . 20-23
Accessories, Polarization Keys . . . . . . . . . . . . . . . 24
Accessories, Test Probe Kit . . . . . . . . . . . . . . . . 25
Connector Installation/User Application Information . . . . . 26-29
Smaller Sized Brush Connectors - Design Flexibility . . . . . 30, 31
Hybrid Configurations with Contact Options . . . . . . . . . . 32
Hybrid Designs, Small Color-Coded Brush Connectors . . . . . . 33
Other Brush Contact Rectangular Connectors:
Docking Connectors . . . . . . . . . . . . . . . . . . . 34
HDB High Density Brush Connectors. . . . . . . . . . . . . 35
3
Low Mating &
Unmating Forces
• Smooth, low friction
interfaces
• 70% to 90% reduction in
mating/unmating forces
from conventional
pin-socket contacts
• 1.5 oz. maximum forces per
contact pair (one ounce
typical)
• Easy mating/unmating
makes high circuit counts
practical (25 lbs. typical for
400 contacts)
• Mechanical mating aids not
required
• No need for external board
support structures for con-
nectors up to 7 inches long.
A center support is recom-
mended for Mother Board
Connectors over 7 inches.
Proven Durability and
Long Contact Life
• 100,000 mating cycles,
even when hot swapped
• Documented intermittency
free performance –
no 10 nano second discon-
tinuities during 50m cycles
of 0.010 displacement
• Overall cost effectiveness
(reduced life cycle costs)
HSB
3
High Density Brush Connectors. . . . . . . . . . . . . 36
Ruggedized Rack and Panel Connectors . . . . . . . . . . . 37
LRM (Line Replaceable Module) Connectors . . . . . . . . . . 38
LRM Hybrids and High Speed LRM Gigastak & Digastak . . . . . 39
Other Rectangular Connectors:
Total Packaging with Amphenol Printed Circuit Boards,
Rectangular and Cylindrical Connectors . . . . . . . . . . . . 40
Amphenol Sales Office and Distributor Listing . . . . . Inside Back
Multiple Points of Contact
Provide Superior
Electrical Capability
• 14-70 points of contact per
mated contact
• Stable, low resistance – 20
milliohms max.
• Redundant current paths
results in lower total resis-
tance
• Proven electrical and gas
tight contact sites
Please note that, in the future, this catalog will be part of Amphenol’s New
Combined Rectangular Interconnect Catalog. Call Amphenol Aerospace for
more information about this combined catalog, to be available Jan. 2011.
Amphenol Low Mating Force
Rectangular Connectors
MIL-DTL-55302
(M55302/166 thru /172)
Amphenol’s Low Mating Force Connectors are well known in the connector arena – with proven performance on the
ground, in the air, and at sea. – In service for over 25 years, with over 50 million brush contacts fielded; and qualified for
use on M1A2 Abrams, F-16 Falcon, F/A-22 Raptor, F-35 Lightning II, AIM-132 ASRAAM and many more applications.
Four Standard Body Styles
Mother Board
Input/Output
Daughter Board
PC (“Right Angle Mother Board”,
“Card Extender”)
Key Connector Features
• 0.100 inch center to center, square grid contact spacing
• Application flexibility (parallel boards, perpendicular boards, wire to
board, end to end boards, card extenders
•
2, 3 and 4 row contact arrangements with 10 to 100 contacts per row
in one contact per row increments
•
Military versions meet MIL-DTL-55302/166 through /172
• Termination versatility; straight & 90° PCB stud, wire wrap & crimp
•
Options on termination lengths and plating
• Front release/front removable contacts in Mother Board, Daughter
Board and PC version; rear release/rear removable crimp contacts
(size 22D) or printed circuit board pins provided with Input/Output
connectors
•
Accessories available for latching and polarization
•
Up to 256 keyed, mating polarizations available
• Hybrids available – mix signal with power, RF or fiber optics
•
Smaller sized connector designs with as few as 5 contacts per row
•
RoHS compliant versions are available, consult
pheno
l
Am
Amphenol Aerospace for more information
oHS
R
Unmated Input/Output and PC Connector
Performance
•
voltage rating:
•
•
•
•
•
•
U
SL
70,000 ft.
1300
325
one and one-half ounce max. average contact engaging/
separating forces
7 million average contact resistance for row A contacts
(Resistance will vary depending on the point of measurement and the
length of the contact.)
3 ampere – PCB contacts; 5 ampere – wire wrap / crimp contacts
–65°C to +125°C temperature rating
5 gigaohms minimum insulation resistance
E
/2
002
/
95
/
Materials
• Connector Body – Glass-filled thermoplastic molding material in
accordance with MIL-M-24519 type GPT-15F and/or Grade B,
• Class 15 of MIL-P-46161 (UL94V-O)
• Polarization Keys – Glass-filled acetal plastic molding material in
accordance with MIL-P-46137
• Locking Screw/Mounting Bushing – Corrosion resistant steel AISI
300 types passivated in accordance with QQ-P-35
An Input/Output and Mother Board Connector
Contacts
• Holders – Copper alloy in accordance with Federal Specification
QQ-B-626 or SAE J463
• Wire – Berryllium copper in accordance with Federal Specification
ASTM B197
•
Sleeves – If applicable, stainless steel in accordance with
AMS-5514 passivated in accordance with ASTM A967
1
C
E
1
Mated Mother Board and Daughter Board Connector
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PCB Design
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