PacAero’s hermetic family of hermetic Micro-D (.050 contact pitch) connectors is compatible with lightweight materials such as aluminum and titanium, as well as conventional iron/nickel alloys. These MIL-PRF-83513 compliant DC connectors are designed for use in military, space, and commercial applications where environmental conditions require an extremely rugged and reliable hermetic seal. The unique controlled CTE characteristics, chemical bonding properties and polycrystalline structure of Kryoflex,® allow PacAero to manufacture this part with a 304L stainless steel insert and gold-plated beryllium-copper contacts for excellent electrical performance and environmental characteristics. These hermetic connectors can be produced for both laser-weld and solder-in applications.
PacAero also offers a non-magnetic hermetic Micro-D connector for use in harsh
environments where superior hermetic integrity and non-magnetic characteristics are crucial to a component’s design. The connector’s shell is comprised of titanium and Inconel because this metal combination delivers the strength, expansion coefficients and low magnetic permeability required. These metals are joined using PacAero’s unique explosive metal bonding processes. Pin material options include Inconel, molybdenum or titanium.
For applications where weight is a key consideration, PacAero now manufactures an aluminum Micro-D connector that’s approximately 67% lighter than stainless steel alternatives. The aluminum Micro-D connectors have an operating temperature range of -55°C to +125°C and uses PacAero’s industry-proven polycrystalline ceramic-to-metal sealing technology, Kryoflex, to achieve a leak rate of less than or equal to 1×10-5 cc/sec He at one ATM.
PacAero’s hermetic Micro-D connectors leverage High Temperature Co-Fired Ceramic (HTCC)
technology. PacAero’s newest Micro-D connector’s external interface resembles a standard rectangular connector, with rows of sockets providing an electrical connection. In this new, patented design, however, the external sockets are mated to a specially engineered HTCC board that integrates metalized circuit patterns, rather than traditional pins. This approach can save space and reduce wire-bonding complexity while still maintaining PacAero’s high standards for harsh-environment reliability and electrical performance. All PacAero hermetic Micro-D connectors are manufactured to exceed the requirements of MIL-PRF-83513.
PacAero’s Mini-Micro-D connectors are designed for space, airborne, down-hole oil and any other hermetic applications where reducing size and weight are priorities. They have a 27% lower profile than standard Micro-D connectors are designed to be laser welded into aluminum, titanium or kovar housings. These new connectors are MIL-PRF-83513/7 interface compliant and mate with connectors manufactured to MIL-PRF-83513/8.
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Hermetic Micro-D Connectors: Specifications and Testing Configuration
Performance Configurations | Micro-D |
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| Low Profile Flanged | Low Profile Not Flanged | Standard Profile Flanged | Standard Profile O-RING Flanged | Standard Profile Double End | Standard Profile Solder |
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| Specifications | Material Compatibility | Designed for Aluminum, Titanium or Iron/Nickel Alloy applications |
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| Contact Material | Beryllium Copper CDA Alloy 172/173 |
| Shell Finish Options | Passivated, Nickel/Gold Plated or Chromate Conversion Coated as applicable |
| Contact Finish | Nickel/Gold Plating |
| Interface | Per MIL-PRF-83513 |
| No. of Contacts | 9, 15, 21, 25, 31, 37, 51, 100 |
| Opt. Solder Cup | Accepts 24-30AWG solid/stranded wire |
| Performance | Leak Rate | Less than 1X10-9cc/sec Helium at 1 atmospheric differential pressure |
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| Thermal Cycling | Tested to 500 (minimum) thermal cycles without hermetic performance loss |
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| Insulation Resistance | Connectors provide greater than 5,000 Megohms at 100 VDC when tested in IAW EIA 364-20 |
| Dielectric Withstanding Voltage | Connectors exhibit no evidence of breakdown or flashover when tested in EIA 364-20 |
| Corrosion | Connectors meet salt spray test in IAW MIL-STD-1344, Method 3003 |
| Operating Temperature | -65°C to 200°C |