ITT Interconnect Solutions has developed a custom, highly durable and low-cost MIL-DTL 38999 Series II connector that features a contact for a printed circuit board and a rear seal for use in corrosive environments. Constructed to customer specifications, the interconnect solution was not only designed to be intermateable with standard MIL-DTL 38999 connectors, but also to withstand thermal cycling and exhibit air pressure sealing to a mandatory 5 PSI.
ITT engineers created the MIL-DTL 38999 Series II connector as a modification of an existing product, thus reducing the cost of custom tooling for the customer. ITT engineers re-designed the rear insulator and shell of a Mil-DTL 38999 Series II series connector to incorporate an epoxy compound, creating a low-cost alternative to a hermetic product by evaluating many epoxy compounds in order to meet the customer's stringent testing requirements.
The project had to run on a tight timescale during both the design and manufacturing stages, which was achieved by close cooperation between ITT design engineers and the manufacturing facility. The teamwork proved flexible enough to accommodate two customer design changes during the project.
Applications for the low-cost hermetic custom MIL-DTL 38999 connector with printed circuit board contact include: military communications systems, such as portable radios and military vehicle radios.