Hermetic Connectors

PacAero designs and manufactures a wide variety of hermetic high-reliability connectors, DC & RF connectors, machined housings and integrated hermetic electronic packaging for use in extreme environments that demand superior mechanical and electrical performance. 

Hermetic, high-reliability connectors manufactured by PacAero are essentially designed to perform two functions: to carry signal or current in and out of an electronic package and to ensure no outside elements can enter the electronic package. 

In general, the degree of protection varies by connector design, construction and materials. Environmentally sealed connectors are designed to stay sealed in relatively benign surroundings such as underwater or in changing weather. The degree of protection these types of connectors offer can be defined by an Ingress Protection Rating standard. For example, an IP 68 rated connector will not allow the ingress of dust or water at 1+ meter immersion. 

Defining Hermetic

Merriam-Webster defines hermetic as ‘being airtight or impervious to air’ and hermetic connectors are PacAero’s area of specialization. But even that seemingly straight forward definition is subject to interpretation, because essentially, no seal is absolutely air tight.

The common method for measuring a connector’s leak rate involves forcing helium through a connector in a vacuum environment. PacAero typically defines ‘hermetic’ as a leak rate of less than 1×10^-9 (0.000000001) cc per second of helium at 1 atmospheric differential pressure. Other manufacturers consider higher leak rates as high as 1×10-5 hermetic where PacAero considers anything below 1×10-9 ‘semi-hermetic.’

Hermetic Connector Drivers

A hermetic high-reliability requirement connector is typically driven by three key factors: 

1. Tolerance for risk: Repair or replacement in the field is risky, difficult or impossible costly production delays or service disruptions are unacceptable, mission-critical applications that can’t fail
2. Environmental factors: Extremely high or low temperature exposures, high pressure environments, and corrosives
3. Susceptibility of sensitive electronics to: Pressure Temperatures and gassing

PacAero’s interconnect products are designed for use in defense, space, medical and commercial applications where environmental conditions make an extremely rugged and reliable hermetic seal an absolute requirement. They are hard at work in life-supporting medical devices, oil-drilling tools deep below the earth’s surface, stealth fighter aircraft, and in many other demanding applications. 

PacAero’s approach to hermetic interconnect designs provides maximum versatility which can lower over-all product cost. PacAero utilizes unique materials in its manufacturing processes and offers a range of manufacturing capabilities – machining, plating, vacuum brazing, laser welding, and more — at a single location. This integrated manufacturing approach can reduce complexity and risk on your next project. We have a talented staff of application engineers with deep experience in developing and manufacturing custom solutions for extreme environments who are ready to assist you with your next project. Let us know how we can help. 

Extreme applications require components that perform flawlessly and retain their original properties even in the harshest of environments. PacAero’s hermetic DC connectors and RF connectors can withstand mechanical and thermal stresses that far exceed the limits of most conventional interconnection solutions.

Hermetic High-Reliability Connector Configurations

Hermetic High-Reliability RF Connector Configurations