Electrical Connector and Wire Harness Manufacturing
Founded in 1988, Connectronics Corp. began operations as a designer and manufacturer of connectors and interconnect solutions for customers in a wide range of industries. Since then, we’ve committed ourselves to continually improving our products and processes. This mindset, in conjunction with our over 300 years of combined connector and interconnection system experience across a diverse set of industries, gives our team the knowledge and skills they need to meet customer needs with superior products and services.
Both connectors and wire harnesses play a critical role in many electrical assemblies. A wire harness is a collection of cables or wires used to transmit electrical power, signals, and data, while connectors—also known as electrical connectors—are end components used to join wire harnesses and other devices to a circuit or power source to enable their function. The latter comes in a variety of shapes, sizes, and configurations with different methods of making connections to circuit contacts (e.g., board mount, crimp, and wire wrap) to suit different use cases.
While the broad selection of connectors available ensures there is an appropriate option available for each application, it also makes it more challenging to determine which one is ideal. Partnering with an experienced connector supplier helps streamline the process.
Connectors From Connectronics
At Connectronics, we offer an extensive range of connectors suitable for use in a variety of industrial applications, including:
Our high-voltage connectors are designed for reliability when handling operating voltages ranging from 5 to 60 KVDC in temperatures ranging from -55° C to +150° C and elevations up to 70,000 ft. They also demonstrate resistance to corona, radiation, shock, and vibration and conform to military specifications for materials specifications. They can be assembled in the factory or the field as needed.
For additional information about these connectors, visit our high-voltage connectors product page.
Our high-current connectors are capable of carrying exceptionally high levels of current in temperatures ranging from -40° C to +175° C and at elevations up to 10,000 ft. They are available in the following models:
Flash Lamp Series
Our flash lamp connector series features low-cost, high-current connectors ideal for use in applications where weight, temperature, and space are critical concerns. They employ Multilam band contact spring finger technology that allows for higher current ratings with lower temperature rise than alternative products. Options for silicone rubber overmolding on contacts are available for an enhanced voltage barrier.
Safety Lock Series
Our safety lock series features power distribution technology designed to facilitate 600 V, three-phase, 200 amp, and 400 amp power. It includes anodized aluminum shells with weather-resistant options and a “first-in, last-out” configuration that ensures operator safety. Ground and neutral connections must be properly connected before the ground safety feature will allow power flow. These connectors are highly efficient and can be installed quickly and efficiently in both stationary boards and field setups.
For additional information about these connectors, visit our high-current connectors product page.
Underwater Cables and Connectors
We offer a full series of underwater cables and connectors complete with stainless steel hardware, O-ring sealed interfaces, and waterproof overmolding. They provide reliable performance for 300 VDC operating voltages in underwater environments with temperatures ranging from -10° C to +80° C.
For additional information about these connectors, visit our underwater cables and connectors product page.
We understand that certain applications require connectors with specific performance characteristics. For this reason, we have designed and developed numerous connectors tailored for use in highly specialized applications. From nuclear and x-ray exposure to space applications and extreme temperatures, our connectors are designed and built to withstand some of the harshest environmental and operating conditions. They accommodate currents up to 1000 amps in environments with temperatures up to 250° C. Applications include equipment for nuclear, space, X-ray, and laser operations.
For additional information about these connectors, visit our specialized connectors product page.
In addition to our connector and interconnect products, we supply Wiremax wire products. Below we provide a brief overview of some of our offerings.
SIL-KOAT Silicone-Coated FEP Wire
SIL-KOAT wire features silicone-coated fluorinated ethylene propylene (FEP) insulation. This design allows for bond compatibility with standard potting materials and adhesives. It is small in diameter, ozone- and corona-resistant, and highly flexible. It offers reliable performance for voltages ranging from 1 to 30 KVDC in temperatures ranging from -55° C to +200° C. Options are available for 28 to 20 AWG conductors and a Nomex braid design for particularly abrasive applications.
High-Voltage FEP Wire
High-voltage FEP wire is suitable for use in applications with voltages from 1 to 30 KVDC and operating temperatures from -55° C to +200° C. It is highly flexible and ozone- and corona-resistant. It is available with 28 through 20 AWG size conductors with silver-plated copper and Nomex braid for abrasive applications. It complies with RoHS and UL94V-O flammability requirements.
We also offer a pre-etched high-voltage FEP wire. It has the same features and performance characteristics as standard high-voltage FEP wire but comes with an etched surface that facilitates bonding with potting materials.
High-Voltage Micro-Bend Wire
These high-voltage, micro-bend wires feature proprietary perfluoroalkoxy (PFA) insulation. They are available with chemical etching for enhanced bonding (ETP) and without etching (ETNP). All designs are constructed with silver-plated copper alloy stranded conductors.
For additional information about our wire offerings, visit our Wiremax product page.
Custom Electrical Connectors and Wire Harnesses
In addition to our standard products, we offer custom design and manufacturing services to customers with highly specific or unique applications. Our experienced designers and engineers use cutting-edge technology to conceptualize and prototype samples for testing prior to proceeding to full-scale production to ensure the delivered products fully meet customer needs.
When taking on a custom connector or wire harness project, our team generally adheres to the following process:
- Consulting with the customer to determine the full scope of wants and needs for the project
- Creating design models using critical specifications to evaluate the product design for engineering analysis and the fabrication of tooling and production fixtures
- Manufacturing prototypes and production-quality components using precision CNC machining equipment
- Conducting inspections at each stage to ensure the highest quality and accuracy standards are met
- Assembling the component to exacting standards
- Analyzing and validating the mechanical and electrical properties of the assembly to ensure it meets all internal and customer standards
- Providing world-class customer service even after product delivery
Our connectors and harnesses find application in numerous industries, including:
- Avionics (Civilian and Defense)
- Oil Exploration
Connector and Wire Harness Solutions From Connectronics
At Connectronics, we are dedicated to providing the best wire harnesses and connectors in the industry. With over 300 years of combined industry experience, we can design, engineer, model, and manufacture standard and custom wire and cable assemblies that meet the needs of a broad range of industrial applications. To learn more about our wire harness and connector product and services offerings, contact us or request a quote today.