Welcome to TESLA Jihlava

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Gwendoline Rogers
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1 HYPCON CONTACTS

The company is certified in compliance with ISO 9001 standard and VDA 6.

TESLA Jihlava provides customers with a comprehensive service including subcontracting of all primary production operations.

2 Welcome to TESLA Jihlava Praha D1 Rozvadov (Műnchen) Jihlava Znojmo (Wien) Brno COMPANY PROFILE TESLA Jihlava, a.s. - a joint-stock company - is one of the largest Czech manufacturers of electromechanical components specializing in the connector- and switch- business since The company is certified in compliance with ISO 9001 standard and VDA 6.1 directive for the automotive industry, authorized to apply the UL Mark for DIN connector series and KEMA approval for switching components. TESLA Jihlava provides customers with a comprehensive service including subcontracting of all primary production operations. Electromechanical Components Product Range: Connectors two-piece rectangular (PCB mount) DIN F, C, H, F+H HYPCON (with hyperbolic geometry) insulation displacement connectors (IDC) for.050" flat ribbon cables coaxial Switches membrane switches push-button switches Custom Components connectors switches other electromechanical components Services: progressive dies for metal stamping, injection moulds design and manufacture jigs & single-purpose machine development and manufacture tailor-made operations in subcontracting range of: - tool-making workshop - moulding workshop - metal stamping workshop - plating plant - precision machining workshop - automation specialized assembly operations

3 HYPCON CONTACTS A multiple linear connection between the pin on the male side and the hyperboloid socket on the female side uses a unique technology. The socket bears a number of contact spring wires wound inside the socket at a small angle to the centre-line, thus forming a one-sheet rotary hyperboloid. When the pin and the socket are mated, the hyperboloid-like socket accommodates the round pin and the wires wrap themselves around the pin to ensure a number of linear tensioned contacts. As a result of this multiple linear connection, an extremely reliable connection is provided even if the connector is exposed to shocks and vibrations (contact interruption < 2 ns). Round pins mated with HYPCON sockets feature considerably low contact resistance of the connection. One of the key benefits is that low insertion and extraction forces allow the connector to reach a long contact life (up to 100,000 mating and unmating cycles). HYPCON CONTACT MANUFACTURE TESLA Jihlava is one of few world manufacturers of contacts with hyperboloid technology. We have been experienced in utilizing HYPCON technology since 1971 when TESLA Jihlava started to manufacture this contact system under licence. The high performance of HYPCON contacts is based not only on know-how transferred from the inventor of this system but also on expertise we have acquired over the years. Most HYPCON contacts are custom designed. On request we can build contacts that differ both in diameter and in shape from those listed in this catalogue. The pin and/or socket body as well as the termination can be adjusted to the requirements of the customer. The design parameters - number, angle and diameter of wires, plating etc. - can be modified to meet requirements on characteristics of the contact. This catalogue lists only representatives of the manufactured assortment of HYPCON contacts. We reserve the right to implement any changes to the parameters and assortment. KEY FEATURES OF HYPCON CONTACTS Low contact resistance (one of the lowest values among existing contact designs) Low insertion and extraction forces Long contact life High reliability, even exposed to shocks and vibrations High stability of electrical and mechanical parameters over a high number of mating and unmating cycles High current and voltage ratings 1

4 APPLICATIONS The above features make HYPCON contacts suitable for safety-critical applications: Avionics, spatial avionics Military Medical appliances Rail traction Testing equipment Industrial applications Communications and data transfer CHARACTERISTICS OF HYPCON CONTACTS Contact diameter: according to customer requirement, no fixed upper limit Rated current: 3 to 70 Amps, higher ampacity on request Contact resistance (typical): up to 2.5 mω Mechanical lifetime: up to 100,000 mating and unmating cycles (type specific) Corrosion resistance: 0.1 % H 2 S within 24 hours or salt spray 96 hours Climatic category: 55/125/56 (other implementation on request) Material (typical): Socket body: gold or silver plated brass Contact wires: gold plated brass Pins: gold plated brass or bronze Retaining clips: stamped: beryllium bronze turned: gold plated brass Termination options: - Straight solder pin for PCB (both for sockets and pins) - Angled solder pin for PCB - Solder cup - Wire wrap post - Crimp termination with / without strain relief (other plating or termination on request) Tab. 1 - Maximal wire gauge (four indenter crimp) Graph 1 - Maximal HYPCON ampacity Diameter of crimp barrel (mm) Max. wire gauge mm 2 AWG to to Note: When crimping always follow recommendations of the crimping tool manufacturer Note: Actual ampacity can be lower due to required design parameters 2

5 BASIC SIZES Note: Socket body can be modified to meet your requirements. Item 1 Description: Pin with retaining clip Part number: WF Item 2 Description: Pin with retaining clip Item 3 Description: Pin with retaining clip Item 4 with retaining clip Part number: WF Item 5 with retaining clip Part number: WF Termination: Solder lug 3

6 BASIC SIZES Note: Socket body can be modified to meet your requirements. Item 6 with retaining clip Part number: WF Item 7 HYPCON 1 Part number: 2 WF Item 8 HYPCON 1 Item 9 HYPCON 1 Item 10 HYPCON 1 4

7 BASIC SIZES Note: Socket body can be modified to meet your requirements. Item 11 HYPCON 1 Item 12 HYPCON 1.5 Description: Pin Part number: WA Retention: Clip WA Item 13 HYPCON 1.5 Description: Pin Part number: WA Retention: Clip WA Item 14 HYPCON 1.5 Part number: WF Retention: Clip WA Item 15 HYPCON 1.5 Part number: WF Retention: Clip WA

8 BASIC SIZES Note: Socket body can be modified to meet your requirements. Item 16 HYPCON 1.5 Part number: 2 WF Item 17 HYPCON 1.5 Part number: 2 WF Termination: Wire wrap post Item 18 HYPCON 2 Part number: 2 WF Item 19 HYPCON 2 Part number: 2 WF Item 20 HYPCON 2 Part number: 2 WF

9 BASIC SIZES Note: Socket body can be modified to meet your requirements. Item 21 HYPCON 2 Item 22 HYPCON 3.6 Part number: 2 WF Item 23 HYPCON 3.6 Part number: 2 WF Item 24 HYPCON 3.6 Part number: 2 WF Item 25 HYPCON 3.6 7

10 BASIC SIZES Note: Socket body can be modified to meet your requirements. Item 26 HYPCON 3.6 Item 27 HYPCON 3.6 Description: Size 8 socket contact 8

11 ATYPICAL CONTACTS Note: Some atypical contacts may not be available in the required volumes or time. Please always consult manufacturer for latest information on particular P/N. Item 28 HYPCON 0.5 Description: Pin Part number: 2 WA Item 29 HYPCON 0.5 Part number: 2 WF Item 30 Description: Pin with retaining clip Part number: 2 WF Item 31 Description: Pin Part number: WA Item 32 with retaining clip Part number: 2 WF

12 ATYPICAL CONTACTS Note: Some atypical contacts may not be available in the required volumes or time. Please always consult manufacturer for latest information on particular P/N. Item 33 w/o retaining clip Part number: 2 WF Termination: Wire wrap post Item 34 w/o retaining clip Part number: 2 WF Item 35 with retaining clip Part number: 2 WF Item 36 with retaining clip Item 37 HYPCON 0.76 Description: Pin Part number: 2 WA

13 ATYPICAL CONTACTS Note: Some atypical contacts may not be available in the required volumes or time. Please always consult manufacturer for latest information on particular P/N. Item 38 HYPCON 0.76 Part number: 2 WF Item 39 HYPCON 0.8 Description: Size 22D socket contact Part number: 2 WF Item 40 HYPCON 1.02 Description: Pin Item 41 HYPCON 1.02 Part number: 2 WF Item 42 HYPCON 1.02 Part number: 2 WF

14 ATYPICAL CONTACTS Note: Some atypical contacts may not be available in the required volumes or time. Please always consult manufacturer for latest information on particular P/N. Item 43 HYPCON 1.02 Part number: 2 WF Item 44 HYPCON 1.4 Part number: 2 WF Item 45 HYPCON 1.6 Part number: 2 WF Item 46 HYPCON 2.5 Part number: 2 WF

15 ACCESSORIES Item 47 Description: Contact retaining clip for removable contacts Part number: WA Item 48 HYPCON 1.5 Description: Contact retaining clip for non-removable contacts Part number: WA

Havlíãkova 30 586 26 JIHLAVA Czech Republic Tel.

16 Havlíãkova JIHLAVA Czech Republic Tel.: Tel./Fax: market@teslaji.cz

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