To address these challenges characterized by harsh environments and high power, Positronic has introduced the Panther family (Panther I – PA series and Panther II – PB series), capable of delivering high performance under all conditions. The combination of highly reliable, high-capacity electrical contacts and advanced materials are key factors in solving power supply problems in the rail, industrial, electric vehicle, and aircraft markets.

Designed for harsh conditions
. The development of connectors intended for harsh environments takes performance into account. Thus, the connector housing must be manufactured from materials capable of withstanding exposure to extreme conditions, physical impacts, and contaminants. The contacts integrated into the connector must withstand strong vibrations to provide a reliable connection. The rubber gaskets surrounding the connector structure must be flexible over a wide temperature range. (Position A)

To achieve this level of reliability, designers must have a thorough understanding of the operating conditions for their equipment, which must withstand shocks, vibrations, and contamination. This could be as simple as rain and water spray, but protection against more aggressive substances is also necessary. Fuel, lubricants, and hydraulic fluids, common in transportation applications, can all affect the safe operation of the equipment.

The Panther connector series is IP69K rated. This means the connector is protected against water, even under high-pressure spray, making the Panther connector ideal for outdoor use. Furthermore, the Panther will function under the harsh conditions found inside a vehicle's chassis and engine. (Position B)

The Right Materials:
Selecting the right insulation material is fundamental to connector design. The insulation in Panther series connectors is a high-performance polymer characterized by its high-temperature stability and mechanical strength, making it ideal for demanding environments. Panther I uses polyetherimide (PEI), with an operating temperature of 160°C, while Panther II is made from liquid crystal polymer (LCP), with a maximum operating temperature of 200°C, considerably higher than other alternative connectors. Both materials offer good resistance to saltwater spray and comply with international railway standards for toxicity and safety against smoke and fire. (Position C)

Both polymer materials allow the Panther connector's insulator to be a single piece. The insulator's trapezoidal design provides polarization to prevent incorrect connection, and the one-piece design speeds up assembly. Both members of the Panther family incorporate stainless steel fittings to provide a positive latch and a secure connection, even in environments with severe shock and vibration. (Position D)

Contacts are fundamental to connector design.
The performance and reliability of a connector depend on the correct contact design and materials. Positronic specializes in manufacturing machined contacts, which greatly impacts connector performance. The electrical contact is machined from solid metal, making it stronger and more durable. A contact with a solid cross-section has more mass, which creates lower electrical resistance and allows connectors to conduct more current while minimizing heat generation. (Position E)

These performance characteristics can be further enhanced by manufacturing contacts with a highly conductive material. The standard contact used by Positronic is a copper alloy. However, the use of copper and tellurium increases conductivity and reduces temperature rise. Copper and tellurium contacts are fitted as standard across the entire Panther family, allowing engineers to take full advantage of this high-performance material.

Closed Input Contacts
Closed input contacts can be obtained through machining. Traditional electrical contacts are typically based on an open input design where the female contact's junction area incorporates a split or bifurcated contact area. This split section is susceptible to potential junction failures or damage from foreign objects that can deform the contact. Such damage reduces the normal force that ensures contact reliability and can decrease electrical performance, especially under adverse conditions. (Position F)

The solid metal machining ensures that the closed input contacts present an uninterrupted ring of solid material towards the contact. This prevents improper contact and damage from other objects, thus improving the connector's mechanical and electrical reliability.

Positronic uses a separate elastic clamp to provide positive elastic force to the contact. Thanks to the contact design, it can be manufactured using copper and beryllium to take advantage of their elastic properties. The smaller size uses Positronic's patented Posiband contacts, while the larger contacts are based on a Large Surface Area (LSA) or Crown Band basket-type design. In both cases, the elastic clamp provides consistent holding force and a large contact surface for optimal conductivity.

Safety First.
Once the technical design elements have been described, it is essential to emphasize that safety is the highest priority for electric vehicles. Modern vehicles, and especially those that use electricity for traction, generate circuits with high current and voltage levels. Without additional safety features, this high power can pose a significant risk to maintenance personnel. The high-power contacts used in Panther connectors are designed with safety in mind. The male contacts incorporate insulating caps, and the female contacts are securely embedded within the connector's insulation, all to ensure that operators cannot accidentally touch live circuits. (Position G)

The development of connectors for rail and public transport applications demands a different set of requirements. While designers must always consider safety, any situation affecting the general public requires an even higher level of safety. Along with electrical safety, designers are aware of the need for products that minimize hazards from fire, smoke, and toxicity. Components designed for use in passenger vehicles must meet stringent standards to ensure their suitability for the application.

Positronic connectors are sold in Spain through Powell Electronics