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Bench Talk for Design Engineers

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Bench Talk for Design Engineers | The Official Blog of Mouser Electronics

Sealed Connectors Meet Complex Design Requirements Sushant Saklani

Sealed Connectors that Answer the Need of the Hour in the Industry

(Source: TE Connectivity)

The world is changing fast, and so are the machines that assist us. With these changes, the components that make up the advanced appliances have become more intricate in designs and require additional protection from the environment in which they operate. The future belongs to more autonomous appliances that are smart in a true sense, requiring them to be robust and tough.

Take an example of a modern-day smart appliance that sends you an alert on your phone and allows you to remotely control the same or a robotic vacuum that functions autonomously. These advanced appliances have brought a surge in demand for deep engineering solutions down to the component level. For example, sealing protection has become an essential requirement for connectors today. Some of the key challenges and industry requirements that shape the market are given below.

Sealing Protection

Better sealing protection means improved reliability of the product. Modern appliances take a technology leap by requiring the components to provide extra protection from dust and water exposure. Smart appliances use enhanced user interface features, and sealed connectors guard that complex internal design. These sealing solutions need to have a high International/Ingress Protection (IP) Rating to better safeguard critical components used in the appliances. The most advanced sealing protection use IP68 or IP67 rating in their connectors.

Miniaturization and Ergonomics

Whether it’s autonomously operating robotic vacuums—household and commercial—or remotely operated smart appliances, the market has seen a considerable reduction in these modern-day appliances’ size and the corresponding connector components. Another key area of improvement is insertion force for mating and un-mating of the components. With improved ergonomics, the surface wear is reduced, and the chances of failure can be decreased significantly.

Clean Process Eliminating Potting

From a sealed connector’s perspective, one of the less-desired processes during sealing is potting. This is because potting requires more time and unnecessary waste that occurs when the entire board is scrapped because of errors. Thus, market trends are pushing the adoption of techniques and products favorable for rework or repair opportunities rather than wasting the materials and the subsequent cost.

Safety Testing

With designs getting more complex and technology advancing at a faster pace, safety becomes more imperative. This is because of the increased frequency of human-to-machine contact and to protect the expensive components used in manufacturing. The necessity of the hour is to ensure that the sealed connectors are well tested for required standards to ensure a safe operating environment for the appliance and serve as a measure to reduce probable cost.

TE Connectivity’s 2.5mm Sealed Signal Double Lock Connector

The enhanced features in today’s appliances are complex and require a great deal of protection from the water and dust around them. TE Connectivity’s 2.5mm Sealed Signal Double Lock Connector offers best-in-class IP67 grade waterproofing, which provides the required protection when designed into applications exposed to high humidity, water, and dust (Figure 1). TE’s sealed connector ensures that it is completely waterproof with no damage to the device’s essential parts.

Figure 1: TE Connectivity’s 2.5mm Sealed Signal Double Lock Connectors offer secondary locking safety combined with IP67 rated sealing protection. (Source: Mouser Electronics)

These waterproof connectors with IP67 grading include ergonomic features to make assembly easier for operators by providing snag-proof latches, polarized terminals, and optional Terminal Position Assurance. With this, there is a significant reduction in insertion force to mate and un-mate the component. As a result, reduced wear and tear further decreases the chances of failure and gives better reliability to the connectors.

Rated up to 3A maximum, and offered in 22AWG to 26AWG, these connectors meet both the UL 94 V-0 and the Glow Wire Test (750°C, no flame) per IEC 60335 flammability standard for global applicability. This is significant for improved safety and cements the quality of the product. It also has a high cost-saving benefit as customers can upgrade to a Glow Wire Testing (GWT) connector for a few cents and eliminate several dollars’ worth of guards.

The last but not the least impressive feature that comes with TE Connectivity’s 2.5mm Sealed Signal Double Lock connector is the elimination of the potting process. It saves the user’s valuable time and reduces WIP both needed for the potting mixture to cure. TE Connectivity’s Sealed SDL is also a great alternative to traditional sealing methods as it’s re-workable and allows for servicing.

The compact 2.5mm centerline spacing offers an ideal solution for miniaturization in today’s connected devices, which requires smaller components and leaves further limited design space within. This is particularly important because constant design challenges need connectors to be further miniaturized, and TE Connectivity answers to it with this product.


Technology in appliances is evolving, and so is the need for miniature components that offer improved ergonomics and fit in more compact designs. And while the process is becoming advanced, the improved sealing protection for these parts has become the need of the hour. Choose the right design solution for those products with TE Connectivity’s 2.5mm Sealed Signal Double Lock connectors.

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Sushant Saklani is an experienced digital marketer, social media manager, and content writer. As a specialist for TE Connectivity, he is responsible for distributor marketing activities for the Appliances and Data in the Devices business units. Saklani holds a Mechanical Engineering degree and an MBA.

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