Amphenol® Bristle Brush Contact:
Multiple Strands of High Tensile Strength
Wires Bundled Together, Providing Superior
Electrical Connection with Low Mating Force
Amphenol’s Broad Family
of Low Mating Force
Interconnect Products
with Brush Contacts
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
Other Similar Rectangular
Connectors from Amphenol
For more information, see additional Amphenol
Rectangular Products at the end of this catalog.
Design Flexibility -
Combination of Brush
Contacts and Fiber
Optic Termini
Combination of Brush
Contacts, Coax and
Power Contacts
Power Strip Connector
Series with cavities for
size 16 or 12 power
contacts (or size 16 or
12 coax contacts).
Hybrid Custom
Connector with Brush
Contacts and
Power Contacts
Docking Connectors -
The Brush Contact
offers high performance
where frequent docking
to charge and transfer
data is a necessity.
High Density
HDB3 and HSB3 Series
LRM (Line Replaceable Module)
Interconnects
Ruggedized
Brush Rack & Panel
Connectors
Ruggedized
VME64x Interconnects
High Speed LRM
Gigastak &
Digastak Inserts
Amphenol® Low Mating Force
Rectangular Connectors
12-035-12
www.amphenol-aerospace.com
Visit our website and see the very broad range of cylindrical and
rectangular interconnection products from Amphenol Aerospace.
Amphenol Corporation
Amphenol Aerospace Operations
40-60 Delaware Avenue, Sidney, New York 13838-1395
Phone: 800-678-0141 or 607-563-5011 Fax: 607-563-5157
www.amphenol-aerospace.com
Amphenol
Aerospace
MIL-DTL-55302
BRUSH CONTACT TECHNOLOGY
use
the same insert bodies as Amphenol low mating force
connectors, but have power contacts rather than brush
contacts. Cavities allow for size 16 or 12 power
contacts. Or, coax/twinax contacts can also be used in
these size 16 or 12 cavities.
COMBINATION OF BRUSH CONTACTS &
SHIELDED CONTACTS
33
Custom Hybrid Designs,
Small Color-Coded Brush Connectors
design exibility
Amphenol can meet innovative connector solutions with
custom designs. Our board level engineers can work with
customers who need special contact arrangements or special
sized inserts.
The special hybrid connector shown at right was developed
for the Vetronics System on a military tank. This custom
shape insert design houses a combination of contact types, a
sealing grommet and it has special mounting/locking screws.
HYBRID CUSTOM CONNECTOR WITH
75 BRUSH DIGITAL CONTACTS,
26 SIZE 16 POWER CONTACTS & 2 SIZE 04 POWER CONTACTS
The following shows a few hybrid congura-
tion connectors that have been developed.
Consult Amphenol Aerospace for assistance
in solving design problems and for part
numbers that will provide the proper
combination of these hybrid congurations
to meet your specic connector application
requirements.
Hybrid: 15 B3 Brush contacts, 4 size 12 power/coax/twinax contacts
Hybrid: 30 B3 brush contacts, 10 size 12 power/coax/twinax contacts
SMALL COLOR-CODED BRUSH CONTACT
CONNECTORS DESIGNED FOR MEDICAL
INSTRUMENTATION
Amphenol has responded to the needs of the medical
industry by offering even smaller inserts with brush contacts.
These small prole, but highly reliable interconnects, are
ideal for medical and test equipment such as patient monitor-
ing systems. Color coding of these connectors was a market-
driven requirement for frequent plugging and unplugging on
equipment, so Amphenol provides these small sized brush
connectors in a variety of color materials.
SMALL COLOR-CODED BRUSH CONNECTORS WITH AS
FEW AS 5 CONTACTS PER CONNECTOR
Hybrid: 30 B3 brush contacts,
6 size 12 power/coax/twinax contacts
Hybrid: 40 B3 brush contacts, 16 size 16 power/coax/twinax contacts
Hybrid: 40 B3 Brush contacts,
4 size 16 power/coax/twinax contacts
Hybrid: 10 B3 brush contacts, 4 size 16 power/coax/twinax contacts
34
Other Brush Contact Rectangular Connectors
Docking Connectors
with (.0787 inch X .100 inch) staggered grid spacing
BRUSH CONTACT CONNECTORS MAKE THE IDEAL
CHOICE FOR FREQUENT DOCKING APPLICATIONS
When frequent docking to charge and transfer data is a
necessity, the brush contact system offers high
performance of over 100,000 mating cycles. This long
contact life without degradation in performance
provides customers with reliability in frequent docking
applications such as:
Performance
Durability: . . . . . . . . Up to 100,000 mating cycles
Insertion/Extraction Force: . 1.5 ounce typical per contact
Operating Temperature: . -65° to 125°C
Current Rating: . . . . . Up to 5 amperes (termination dependent)
Hot swap 1 ampere maximum (load
dependent)
Data Rate
(Select connectors only): . Congurable for 3.125 Gbps differential signal
Insulation Resistance:. . . 5 gigaohms minimum
Dielectric Withstanding
Voltage: . . . . . . . . . 750 volts @ sea level minimum
250 volts @ 70,000 feet elevation min.
Solderability: . . . . . . . MIL-STD-202, method 208
Salt Fog: . . . . . . . . 48 hours IAW MIL-STD-1344, method
1002, type II
Humidity: . . . . . . . . IAW MIL-STD-1344, method 1002, type II
Vibration: . . . . . . . . 4 hours in each of 3 mutually perpendicular
axes IAW MIL-STD-1344, method 2004, test
condition G
Shock: . . . . . . . . . 1 shock along each of three mutually
perpendicular axes IAW MIL-STD-1344,
method 2004, test condition G
Features
Radial Misalignment: . . . Capable of correcting up to a .040” initial
radial misalignment
Angular Misalignment: . . Capable of mating with up to a 4° initial
angular misalignment
Polarization: . . . . . . . “D” shaped interface
Color:. . . . . . . . . . Standard is black, variety of other colors are
available
Materials
Insulator: . . . . . . . . Glass-lled thermoplastic molding
Contact: Wire . . . . . Beryllium copper per ASTM B197; nish is
gold per ASTM B488 over nickel per AMS-
QQ-N-290
Holder . . . . Brass similar to UNS C33500; nish is gold
per MIL-G-45204 or tin-lead per MIL-P-81728
or tin per MIL-T-10727 (RoHS compliant
Sleeve:. . . . Stainless steel per AMS-5514,
passivated IAW QQ-P-35
(DB and I/O connectors only)
Amphenol offers Docking Connectors in a compact
size, with tighter spaced custom brush contacts
(.0787 inch x .100 inch staggered grid spacing).
• Handheld GPS units
• Handheld radios
• Rugged computers
• Controllers
• Scanners
• Accessories
• Cellular phones
2.165 1.056
.486
.079
.551
.021 ±.002 DIA. .250
1.614
.100
.0787
.276
± .005 DIA.
.100
.0394
1.413 1.180
.461
.512
.059 .021
±.002 DIA.
.0787
Mother Board Docking Connector
Daughter Board Docking Connector
For more information, including how to order, consult
Amphenol Aerospace. Call 800-678-0141 and ask for Amphenol
board level product marketing for assistance.
35
Other Brush Contact Rectangular Connectors
HDB3 High Density Brush Series -
tighter (.070 in. X .060 in.) staggered grid spacing
HDB3 CONNECTORS
The new connector series of brush connectors incor-
porates an even higher density contact pattern and
lower mated height than Amphenol’s standard low mat-
ing force rectangular connectors. These HDB3 con-
nectors utilize the same durable and reliable B3 brush
contact, but in a tighter .070 inch X .060 inch staggered
grid spacing. They offer the advantage of a higher
density pattern in a compact-height connector that will
take up less board space; thus saving cost over adding
additional connectors to meet power requirements.
HDB3 connector styles include mother board, daughter
board, input/output and a stacker style.
For how to order information of the HDB3 see Amphe-
nol brochure SL-402* online at www.amphenol-aero-
space.com.
Mother Board/Daughter Board HDB3 Connector
Number
of
Contacts Contact
Pattern A
Max. C
Max.
40 4 Row X 10 1.375 1.075
60 4 Row X 15 1.725 1.425
80 4 Row X 20 2.075 1.775
120 4 Row X 30 2.775 2.475
160 4 Row X40 3.475 3.175
Mother Board HDB3 Connector Daughter Board HDB3 Connector
When more contact density is required, the HDB3 High Density Series
with .070 inch X .060 inch staggered grid spacing is the solution.
* Also in SL-402 brochure are other HDB3 style connectors: input/output style, stacker and high speed congurations.
Please note, the new Amphenol Combined Rectangular Products catalog, 12-R1, will combined 12-035 (this catalog)
and HDB3 product covered in SL-402, along with other Amphenol rectangular interconnect products. Ask for the new
combined Amphenol Rectangular Interconnect Products catalog; available Jan. 2011
CA
.325
.540
.350
.350
.410
.470
.530
C
E
±.020
CONNECTOR
MOUNTING
SURFACE
E ±.020
TYP
123
654
PIN 1
ABC
FED
.035
TYP.
.070
TYP.
.086 MIN. DIA.
THRU HOLE
(USE NO. 2 SCREW)
.350 .086 MIN. DIA.
THRU HOLE
(USE NO. 2 SCREW)
PIN 1
C
A
.335 MAX.
.150 ±.005
.150 ±.020
TYP.
.016 ±.001
TYP.
.195 MIN. HEX
.070 MIN DEEP
(USE 3/16 HEX HEAD)
.090 TYP.
.030 TYP.
4
65
123
D
FE
ABC
36
Other Brush Contact Rectangular Connectors
HSB3 High Density Series with
3.125 Gb/s High Speed data rate
For more information refer to Amphenol® brochure SL-402, on-line
at www.amphenol-aerospace.com. or call 800-678-0141 and ask
for Amphenol board level product marketing for assistance.
HSB3 CONNECTORS
The HSB3 is a further new development of the higher density HDB3
connector series. The HSB3 offers higher speed as well as higher
density. Benets include:
Allows data rates up to 3.125 Gb/s via 100 ohm matched • impedance differential pairs
Uses partially populated HDB• 3 mother board and daughter
board inserts. See HSB3 arrangements below.
HSB3 HIGH DENSITY/HIGH SPEED BRUSH CONNECTOR
HSB3 Insert Arrangements
5
6
11
23
4E
F
ABC
D
5
6
11
23
4E
F
ABC
D
40 Pin Body with 3 Differential Pair, 20 Signal Contacts
80 Pin Body with 7 Differential Pair, 40 Signal Contacts
As viewed from front face of Daughter Board Connector
120 Pin Body with 10 Differential Pair, 60 Signal Contacts
160 Pin Body with 13 Differential Pair, 80 Signal Contacts
5
6
11
23
4E
F
ABC
D
5
6
123
4E
F
ABC
D
1
5
6
123
4E
F
ABC
D
1
60 Pin Body with 5 Differential Pair, 30 Signal Contacts
100 Ohm Differential Pair Contacts
Empty Contact Cavity
Standard Digital, Low Speed Signal Contacts
(100 Ohm Differential contact pairs capable of 3.125 Gb/s data rates)
KEY
37
Other Brush Contact Rectangular Connectors
Ruggedized, Non-Floating Brush Rack and Panel
Connectors
This new connector series utilizes Amphenol’s durable and reliable B3 contact system
in a rugged, non-oating Rack and Panel connector. Included in this series are digital
and power/digital “hybrid” insert arrangements.
Standard Ruggedized, Non-
oating Brush Rack and Panel
Connector Features include:
126 high performance B• 3
brush contacts
0.100 inch x 0.100 inch •
square grid footprint
Environmentally sealed at • connector interface with
mated (optional feature)
Environmentally sealed • connector mounting interface
EMI protection is available at • mounting surfaces and
connector interface
ESD protection is available • - allows use of Class 3
hardened chips (4KV max.
voltage)
BACKPLANE CONNECTOR MODULE CONNECTOR
Standard Ruggedized Brush Rack and Panel
Connector Performance:
Durability: 500 mating cycles•
Insertion/Extraction •Force: 7 lbs. typical
Operating Temp.: –60° to +125°C• Current Rating: 3 amperes •
Hot swap 1 ampere maximum (load
dependant) - non ESD protected version
Insulation Resistance: 1 gagohm minimum• Dielectric •
Withstanding Voltage: 500V, 60 Hz RMS @ sea level
300V, 60 Hz RMS @ 15,000 ft. elevation
Solderability: J-STD-004, -005 & -006•
Salt Fog: EIA-364-26B, test condition B•
Humidity: EIA-364-31B, test method III•
Vibration: EIA-364-28B, test condition III•
Shock: EIA-364-27B, test condition G•
Hybrid arrangements are available as shown in top photo at right, that
utilize a combination of brush contacts and high power RADSOK®
contacts. The photo shows a 74 signal and 6 power conguration. For
other hybrid arrangements and assistance on how to order this
product, consult Amphenol Aerospace.
HYBRD RUGGEDIZED, NON-FLOATING
RACK & PANEL CONNECTOR
(8 RADSOK® HIGH POWER CONTACTS, 72 BRUSH CONTACTS)
2 BAY SHELL CONFIGURATION
RUGGEDIZED, NON-FLOATING RACK AND PANEL CONNECTOR
(126 BRUSH CONTACTS PER BAY)
38
Other Brush Contact Rectangular Connectors
LRM (Line Replaceable Modules)
AMPHENOL CONTINUES TO DEVELOP
INTERCONNECTS THAT MEET THE DEMANDS OF
THE AVIONICS INDUSTRY
Starting with the development of the B3 contact, incorpo-
rated into the low mating force PCB connectors, the LRM
line replaceable module followed as the avionics high
density rectangular interconnect solution. LRM intercon-
nects are combinations of module and backplane inserts,
in one bay, two bay, three bay or more congurations.
LRM products are used on major programs of aircraft and
military vehicles.
This page and the next briey describe the LRM family of
connectors. For complete information please see
Amphenol® High Performance Line Replaceable Module
(LRM) Interconnects catalog, 12-037.*
180 Brush contacts in a Staggered Grid
module insert mounted to a PC Board
STAGGERED GRID LRM CONNECTORS
The Brush contact has superior performance in LRM
interconnects due to its low mating force, stable electrical
performance and extended life. Other LRM features
include:
Backplane versatility: available with through-hole solder • posts or with compliant pins for solderless applications
Wide range of PCB/heat sink accommodations with •
standard surface mount tails or ex termination
Polarization keys - up to 4096 possible keying positions• Superior intermittancy-free performance under vibration• Dielectric withstanding voltage: Staggered grid and •
GEN-X styles: 100 volts at sea level (due to the
incorporation of ESD shield)
Temperature range: suitable for vapor phase soldering; •
normal operating temp. is –65°C to +125°C
Current rating: 3.0A derated to 1.5A typical (dependant •on loading)
LRM CONNECTORS WITH STAGGERED GRID
Provides higher contact density for high speed •
integrated circuitry in SEM-E and custom form factors
180 contact insert pattern grid in 8 rows: 0.100 inch •spacing along the row with 0.050 inch between rows,
rows offset 0.050 inch
Options include various shell designs to accommo-•
date a wide range of PC board/heat sink combinations
Solder tail, wire wrap or compliant contact availability•
Amphenol ESD (Electrostatic Discharge) protection: • Utilization of the Faraday Cage principal to shunt
electrostatic discharge events to the conductive enclo-
sure on which the connector is mounted, thus never
allowing the high voltage, high current discharge
event to reside on any contacts.
Designed for level 2 (ight line) maintenance•
Provides routing channels for backplane•
LRM CONNECTORS WITH STAGGERED GRID
AIRFLOW-THRU CONTACT PATTERN
Accommodate standard B• 3 tails in staggered pattern,
but with increased spacing in the center, and also
provide more airow cooling of inserts; for use with
wider boards, up to 0.425 inch
GEN-X GRID LRM CONNECTOR
LRM CONNECTORS WITH GEN-X GRID
Even higher contact density than staggered grid and improved • electrical performance
All the feature of the 180 contact pattern, including ESD protection•
Available in SEM-E and custom form factors• 236 contact pattern grid in 8 rows: 0.075 inch spacing along the row •with 0.060 inch between rows, rows offset 0.0375 inch
* Amphenol LRM Catalog, 12-037, is on-line at www.amphenol-
aerospace.com. Please note that Amphenol’s New Combined
Rectangular Catalog (available Jan. 2011) will include LRM
interconnects. Call Amphenol Aerospace (800-678-0141) for
more information.
39
Other Brush Contact Rectangular Connectors
LRM Hybrids and High Speed LRM Gigastak
& Digastak Inserts
LRM INTERCONNECTS (SHOWN FROM TOP TO BOTTOM):
LRM Backplane, 2 bays of staggered B• 3 brush contacts and inserts for
size 12 coax contacts
LRM Module with Fiber Optic MT ferrules in one insert and B• 3 Brush in
a differential pair insert
LRM inserts with PC tails•
LRM mating Module and Backplane with MT-PRF-29504 Fiber optic •
termini and B3 Brush contacts
LRM OPTIONAL HYBRID DESIGNS
Custom combinations of digital contacts and ber •
optic termini. Optical performance of ber optic termini
within LRM connectors are the same as termini used
in cylindrical connectors.** Insertion losses range from
.3dB to <1.5dB depending upon launch conditions,
ber NA, ber size and the type of termination. LRM
connectors are available with ber optic termini in the
following congurations:
• Modied MIL-PRF-29504/4, /5, MIL-PRF-14 &
MIL-PF-15 termini - size 16, straight and 90
degree styles
• MT ferrule (2-24 ber lines per ferrule)
• Hybrid arrangements with ber optic and other
contact types
LRM inserts with RF contacts•
LRM power supply modules with 270VDC sections • which are capable of providing corona-free operation
at 100,000 ft.
Designs with high speed shielded contacts - coax, •
triax, twinax, differential twinax, and quadrax contacts
Combinations of power contact, standard brush, high •
power, differential pair brush and ber optic termini
New designs that utilizes the RADSOK• ® high amper-
age socket contact with inserts.
The RADSOK® design is a socket cylinder within the
female contact which has several equally spaced
longitudinal beams twisted into a hyperbolic shape. As
the male pin is inserted, axial members in the female
half deect, imparting high current ow across the
connection with minimal voltage loss. This twisted
hyperbolic grid ensures a large coaxial, face-to-face
surface area engagement.
Incorporation of ex circuits for more versatility of PC • board terminations
Custom shells with multiple bay congurations•
Backplane shell grounding capabilities•
HIGH SPEED LRM GIGASTAK AND DIGASTAK
INSERTS
More and more speed is needed in today’s interconnec-
tion products. Amphenol has recently developed a new
family of high speed LRM connectors that are capable of
achieving data rates in excess of 6.25 Gbps via 100 ohm
matched impedance differential pairs. Each insert
arrangement has been optimized through strategic place-
ment of signal and ground contacts for the perfect
balance of impedance control and cross talk mitigation
for a given data rate. As an enhancement over the
standard LRM, this new series offers a unique solderless
termination to module cards via Amphenol Intercon’s
cStack technology.
** For more information on Amphenol ber optic connectors and
termini, see the Fiber Optic section of Amphenol’s Combined Circular
Interconnects catalog, on-line at www.amphenol-aerospace.com.
HIGH SPEED LRM GIGASTAK AND DIGASTAK INSERTS
40
Other Amphenol Rectangular Connectors
Total packaging with Amphenol Printed Circuit
Boards, Rectangular and Cylindrical Connectors
AMPHENOL PRINTED CIRCUIT BOARDS
AMPHENOL PRINTED CIRCUIT BOARD CAPABILITIES
Amphenol Printed Circuits’ capabilities are among the world’s broadest and
most advanced, delivering consistent quality and reliability for demanding high
bandwidth systems and mission critical applications. Designs of printed circuit
boards are available from Amphenol APC with a wide variety of materials,
formation types, panel sizes and layer counts.
AMPHENOL FLEX CIRCUIT ASSEMBLIES
Amphenol Printed Circuits’ capabilities also includes the design and manufac-
ture of ex circuits used to attach cylindrical and rectangular connectors to PCB
boards. Sculptured® Flexible Circuits with built-in terminations eliminate the
failures associated with crimped or soldered-on contacts. Flex geometrically ts
tight space requirements and eliminates the need to purchase and attach
individual pins or connectors.
Consult APC, Amphenol Printed Circuits, for more information on
printed circuit boards and ex assemblies. Phone: 603-324-4500
FLEX CIRCUITRY WITH RECTANGULAR
CONNECTORS
INTEGRATED SYSTEM PACKAGING
Amphenol can provide system solutions - everything you need
inside and outside the box: Interconnect products, printed circuit
boards, backplane assemblies, heat-sinks and metal enclosures.
Amphenol also provides value added assembly including bussing;
full system assembly including chassis build and sub-system
integration and testing. The breadth of Amphenol’s products and
the proven expertise of being a world-wide interconnect product
leader makes Amphenol the premier choice for system-level
packaging. For more information on integrated systems, call:
Amphenol Aerospace at 800-678-0141
Amphenol Backplane Systems at 888-318-3553
AMPHENOL INTEGRATED SYSTEMS
BOARD LEVEL CONNECTOR WITH COMPLIANT PIN
QUADRAX CONTACTS
BOARD LEVEL CONNECTORS WITH QUADRAX CONTACTS
Amphenol leads in the electrical connector arena in offering a wide range of
interconnects that provide high speed transmission and operate in high
frequency conditions. The photo at right shows a board level connector with 4
size 8 quadrax compliant contacts. This will accomodate a backplane of .125
inch min. thickness. Consult Amphenol Aerospace for more information.
VIPER® INTERCONNECTS
Amphenol Backplane Systems (ABS)
developed the VIPER interconnect platform
to provide a ruggedized and high density
modular connector solution that can scale to
higher bandwidths; from 80 Mbps to over 10
Gpbs. Features and benets of the VIPER
include:
Designed for 10+ Gbps data rate • performance
100 ohm impedance for differential pair •
in a 1.8mm x 1.35mm grid
Press-t termination compliant pins•
Backplane modules available in 8 & 16 •
row increments, 1.8mm x 1.8mm grid
Fully footprint-compatible with VITA 46 & VITA 48 standards•
ESD protection•
Consult Amphenol Backplane Systems for more information.
Phone: 603-883-5100
VIPER® CONNECTORS
An example integrated system box, shown at right, includes the following Amphenol
interconnect products:
Circulars: D38999 cylindrical connectors with MT ber optics, RJ Field connectors• Rectangulars: LRM interconnects, NAFI connectors, UHD connectors • Rectangulars: ARINC 600 connectors, Micro-D Subminiature connectors•
Rectangulars: HDB3 high density brush contact connectors•
Backplane Systems, Flex Circuitry, metal enclosure•