Comprehensive Guide to GX Series Connector Cable Assemblies: Materials, Manufacturing, and Applications

1. Product Overview: GX Series Connectors

The GX Series, including the GX16 Aviation Connector, is renowned for its robust design and adaptability. These connectors feature a circular interface with pin configurations ranging from 2 to 8 pins, supporting voltages up to 250V, and currents up to 15A, depending on the model 39. Key attributes include:

• IP67/IP68 Waterproof Ratings: Ideal for harsh environments, ensuring resistance to dust, moisture, and submersion56.
• Material Excellence: Zinc alloy shells, brass contacts, and PBT (Polybutylene Terephthalate) insulation ensure longevity and reliable conductivity 38100.
• Customization Options: Tailored cable lengths, wire gauges, and branding (e.g., logo imprinting) are available to meet specific project needs58.

2. Materials and Construction

A. Shell and Housing

The outer shell of GX connectors is typically made from zinc alloy or nickel-plated brass, providing exceptional mechanical strength and corrosion resistance39. For high-temperature applications, phenolic plastics or black bakelite are used as insulating materials, capable of withstanding temperatures from -40°C to +105°C910.

B. Contacts and Conductivity

Contacts are crafted from brass with tin, silver, or gold plating to minimize resistance (≤5MΩ) and enhance signal integrity910. The GX16 model, for instance, supports currents up to 15A, making it suitable for power transmission in industrial machinery9.

C. Cable and Insulation

Cables are available in PVC or PUR sheathing for flexibility and resistance to abrasion, oils, and UV exposure8. PBT insulation ensures stability in high-voltage scenarios, with insulation resistance exceeding 1000MΩ39.

3. Manufacturing Process

The production of GX Series connectors involves precision engineering and stringent quality control:

• Die-Casting and Machining: Zinc alloy shells are die-cast and CNC-machined to achieve tight tolerances9.
• Contact Plating: Brass contacts undergo electroplating (nickel, silver, or gold) to reduce oxidation and improve conductivity10.
• Insulation Molding: PBT or phenolic plastics are injection-molded around contacts to create heat-resistant barriers3.
• Assembly and Testing: Components are assembled manually or via automated systems, followed by rigorous testing for insulation resistance, waterproofing, and durability69.

Manufacturers like Shenzhen Wanke Electronic Technology Co., Ltd. emphasize lean products and offer a supply capacity of up to 10,000 units daily49.

4. Applications Across Industries

A. Aviation and Aerospace

GX16 connectors are widely used in avionics because of their vibration resistance and IP67-rated waterproofing. They ensure reliability in cockpit systems and ground support equipment46.

B. Automotive and Audio Systems

These connectors facilitate secure connections in automotive applications, such as LED lighting, sensors, and infotainment systems. The 4-pin GX12 variant is popular in audio equipment for its noise-free signal transmission 810.

C. Industrial Automation

GX connectors integrate seamlessly into robotics, CNC machines, and PLCs, where high-current handling and dustproofing are critical 39.