AUTOMOTIVE

End Uses

• Sensor terminals for throttle position, key warning, fuel level, airbags, wheel position, anti-theft, exhaust gas monitors
• Engine compartment power connectors for lights, horn, relays, fans
• Coaxial connectors for GPS systems, internet access, collision avoidance radar, cell phone, satellite radio
• Signal connectors for engine control computers, anti-lock brake modules, comfort controls, displays
• Relays for climate control, wipers, starter motor
• Switches for windows, locks
• EMC shielding to insure interference-free operation of high frequency components
• Armature springs for electric motors for seats, windows, mirrors, fuel pumps and automatic transmission shifting solenoids

Why Copper Beryllium?
Copper beryllium’s high strength, high conductivity and excellent resistance to elevated temperatures provide designers a material that not only performs, but is reliable in miniaturized designs. Its combination of strength and formability allows for complex designs and reliable crimp terminations while providing the contact force required for a stable contact interface. The Connector Design Tutorial demonstrates copper beryllium’s advantage over other copper alloys when applied as the material of choice for an automotive box terminal. Copper beryllium is available in convenient, pre-heat treated strip tempers.

User Benefit / Solution
Copper beryllium is specified in automotive connector designs for its ability to provide reliable service under extremely demanding operating conditions, including vibration, high temperature, high current and difficult environmental conditions. Components made with copper beryllium ensure reliable performance over the life of the vehicle beyond the warranty period. Benefits accrue to consumers through the vehicle makers’ need to meet stringent regulations for fuel efficiency, emissions and safety. Many of the recent comfort and convenience features found in automobiles rely on the performance of components using copper beryllium.

Copper beryllium's unique properties allow automotive connector engineers the flexibility to design ever smaller components while insuring the reliability demanded by consumers and the economy demanded by vehicle manufacturers. The proper combination of connector alloy, coating and component design allow designers to effectively address the issues that can lead to performance problems. In particular, copper beryllium alloy, Brush 60®, is increasingly specified in high reliability automotive connector applications. New applications, such as the use of coaxial connectors for high frequency electronic equipment, rely on copper beryllium alloys, such as Brush M25, that have enabled the development of wireless telecommunication technology for the automotive sector. Detailed design information and considerations in automotive electronic component design can be found in Automotive Technical Tidbits. Additional information on coating technology to enhance corrosion resistance and connector performance is available from Brush Wellman subsidiary, Technical Materials Inc., TMI, located in Lincoln, Rhode Island.

Copper beryllium products provide the technology enabler for the emerging 42-volt PowerNet and vehicle telematics. Forty-two(42)-volt PowerNet improves vehicle fuel economy and reduces tailpipe emissions by transferring engine loads such as braking, power steering and air conditioning to electric motor drives. Telematics combines the power of computers, wireless satellite communications and entertainment to provide a safer and more enhanced driving experience.