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Contact resistance with relation to the number
of mating cyles
(measured according to IEC 60512-2 test 2a)
Average values measured after the mating cycles and the
salt spray test according to IEC 60512-6 test 11f.
Insulation resistance between the contacts
and contact/shell
(measured according to IEC 60512-2 test 3a)
A?
(mm)
Contact resistance (m ? )
1000 3000 5000
cycles cycles cycles
A?
(mm)
Contact resistance (m ? )
1000 3000 5000
cycles cycles cycles
Insulating material
new
Multipole
PEEK
> 10 12 ?
Unipole
PTFE
> 10 12 ?
0.5
7.5
8.3
8.7
3.0
2.0
2.2
3.1
after humidity test 1)
> 10 10 ?
> 10 10 ?
0.7
0.9
1.3
1.6
5.6
4.1
2.8
2.6
5.7
4.2
2.9
2.7
6.1
4.8
3.6
3.5
4.0
5.0
6.0
8.0
1.6
1.4
1.2
0.8
2.0
–
–
–
2.8
–
–
–
2.0
2.9
3.1
3.3
12.0
0.7
–
–
Note: 1) 21 days at 95% RH according to IEC 60068-2-3.
Solder contacts
The conductor bucket of these contacts is machined at an
angle to form a cup into which the solder can flow.
See page 7 for the range of cable dimensions that can be
soldered.
Crimp contacts
The square form crimp method is used (MIL-C-22520F,
class I, type 2) photo 1 for unipole contacts.
For multipole contacts the standard four identer crimp
method is used, MIL-C-22520F, class I, type 1), photo 2.
The crimp method requires a controlled compression to
obtain a symmetrical deformation of the conductor strand and
of the contact material. The radial hole in the side of the con-
tact makes it possible to check whether the conductor is
correctly positioned within the contact. A good crimping is char-
acterized by only slightly reduced conductor section and
practically no gap.
Advantages of crimping
– practical, quick contact fixing outside the insulator
– possible use at high temperature
– no risk of heating the insulator during the conductor-
contact fixing
– high tensile strength
Crimp contacts are available in standard version (form 1) for
mounting maximum size conductors.
For some dimensions, these crimp contacts can be pro-
duced with reduced crimp barrels (form 2) for mounting
reduced size conductors.
For optimum crimping of bronze or brass contacts they are
annealed to relieve internal stress and reduce material
1
2
3
hardening during the crimping process.
Only the crimping zone is annealed with the help of an
induction heating machine designed by the LEMO Research
and Development Department (see photo 3).
Crimp contacts
The crimp contacts can be with two forms: a standard crimp
barrel for large conductors (see fig. 1) or with a reduced
crimp barrel for smaller conductors (see fig. 2).
Fig. 1
www.lemo.com
The range of cable dimensions that can be crimped into
our contacts are indicated on the table on page 7.
Fig. 2
177
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