Engineering insight
Use the following as an early selection reference. Specific models, datasheets and samples should be confirmed with actual structure drawings.
01
Contact resistance test methods
Contact resistance is typically measured using the four-wire (Kelvin) method to eliminate test lead resistance. Standard test current is 100mA or 1A, with measurement voltage below 20mV (dry circuit conditions) to avoid damaging contact surface films. Both initial measurements and post-cycling measurements should be recorded.
02
Factors affecting contact resistance
Contact resistance is affected by contact material, surface plating, normal force, mating cycles, temperature, humidity and contaminants. Gold-plated contacts typically start at 10-30mΩ, tin-plated at 20-50mΩ. A 50% reduction in normal force can increase contact resistance 2-5x.
03
Reliability test items
Connector reliability testing typically includes: mechanical durability (500-5000 cycles), temperature cycling (-40°C to +85°C), humidity cycling (40°C/93%RH), vibration testing and salt spray testing. Post-test contact resistance change should not exceed 50% of initial value, with no visual damage or conduction failure.