Development of electrical insulation for MIL-C-26500 (USAF) electrical connectors

Miniature electrical connectors manufactured in conformance to Specification MIL-C-26500 (USAF) are designed as two separate units which when mated provide for multiple electrical circuits having the ability to perform satisfactorily during extreme environmental condition. The outstanding features of this development are the physical size and performance achieved under extreme environmental conditions. The paramount development responsible for accomplishing these features is the composite dielectric material. The results obtained from this development contract plus supporting manufacture experience have shown that composite dielectric construction of resilient silicone and hard epoxy dielectric possess the necessary electrical and mechanical properties to meet the requirements of MIL-C-26500 (USAF). In addition, the resilient silicone developed by Amphenol incorporates sufficient mechanical strength to permit mold construction employing acute discontinuities in combination with .025 inch molded sections. Resilient silicone and hard epoxy are chemically bonded to form integral dielectric inserts which provide for environmental sealing at both the mating surfaces of the connector assembly plus the wire termination scaling areas. Correspondingly the contact retention device is housed internally in the integral and/or composite inserts. Bonding of the intersurfaces which form the interfaces between the three dielectric insert components eliminating air voids thereby protecting the connectors from degrading environmental conditions.