YF8-42ZJ or TK Separation (Breakaway) Electrical Connector

YF8-42ZJ/TK Separation (Breakaway) Electrical Connector | Miniaturized High-Density 42-Contact Design​​​​​​​

The YF8‑42ZJ/TK Separation Connector series delivers exceptional circuit density in a miniaturized, breakaway package optimized for the most demanding aerospace applications. Featuring 42 size‑22# contacts rated at 5 A each, this connector provides ample capacity for complex signal and low‑power interfaces while maintaining an exceptionally small footprint. With an extended operating temperature range of -65 °C to +200 °C, it surpasses standard military specifications for thermal extremes. Crimp termination ensures reliable, production‑friendly assembly, and the calibrated <80 N separation force guarantees positive release when commanded. With proven resistance to vibration, shock, and acceleration, the YF8‑42 is ideally suited for launch vehicle umbilicals, stage separation, and any application where space is limited but reliability and temperature tolerance cannot be compromised.

Product Descriptions from the Supplier

The YF8‑42ZJ/TK Separation (Breakaway) Electrical Connector is a compact, high‑density interconnect solution designed for applications requiring multiple signal circuits within a single separation interface, combined with extended temperature capability. Fully compliant with enterprise standard Q/21EJ1292, this connector features 42 size‑22# contacts rated at 5 A each, making it ideal for discrete signals, low‑power circuits, and control interfaces where space is at a premium.

All contacts are terminated via crimp technology, ensuring reliable, repeatable connections suitable for high‑volume production and field maintenance. The mechanical separation mechanism is calibrated to release with a force of less than 80 N, providing a secure hold during operation while ensuring positive separation when commanded.

A standout feature is the extended temperature range: -65 °C to +200 °C, surpassing the standard -55 °C to +125 °C range found in most aerospace connectors. This makes the YF8‑42 suitable for extreme thermal environments, including engine-adjacent applications and deep-space thermal cycling.

Engineered for harsh environments, the YF8‑42 survives severe dynamic conditions: random vibration of 0.3 g²/Hz, shock of 20 g, and constant acceleration of 490 m/s². With a mechanical life of 500 mating cycles, these connectors are suitable for ground testing and operational reuse.

Dielectric withstanding voltage is 1300 V AC rms at sea level, derated to 500 V under damp heat and 300 V at low pressure (4.4 kPa). Insulation resistance is exceptionally high at ≥5000 MΩ at room temperature, remaining ≥20 MΩ after temperature extremes and humidity/mechanical testing—ensuring long‑term reliability even after harsh environmental exposure.

Available in two configurations:

• YF8‑42TK: Plug (cable‑attached half) with socket contacts
• YF8‑42ZJ: Receptacle (panel‑mount half) with pin contacts

Typical applications include launch vehicle umbilicals, avionics separation interfaces, UAV tether release, and any system requiring a dense array of signal circuits in a breakaway package with extended temperature capability.

Specifications

Applications

• Aerospace Launch Vehicles: High-density umbilical disconnects with extreme temperature requirements.
• Missile Systems: Guidance and control interfaces in thermal extremes.
• Unmanned Vehicles: UAV tether release for high-altitude operations.
• Avionics: Separation interfaces between cockpit and ejectable modules.
• Satellites: Stage separation and payload deployment with wide thermal cycling.
• Engine-Area Sensors: Near-engine connections requiring 200°C capability.

Functionality

• All-Signal Contact Set: 42× 22# contacts rated at 5 A each for power and signal circuits.
• Extended Temperature Range: -65 °C to +200 °C—wider than standard military specifications.
• Controlled Separation Force: Calibrated <80 N breakaway ensures secure hold yet positive release.
• Crimp Termination: Reliable, production‑friendly terminations for all contacts.
• Miniaturized Design: Ultra-high contact density in a compact footprint—ideal for space‑constrained applications.
• Environmental Robustness: Withstands extreme temperature, vibration, shock, and acceleration.
• High Contact Count: 42 circuits in a single separation interface reduces system complexity.

Key Features

• High-Density All-Signal Design: 42 contacts in a compact shell for complex signal interfaces.
• Extended Temperature Range: -65 °C to +200 °C—surpasses standard -55 °C to +125 °C specification.
• Calibrated Separation Force: <80 N ensures reliable release.
• Crimp Termination: Reliable, repeatable, and suitable for automated assembly.
• 500‑Cycle Mechanical Life: Adequate for ground testing and operational use.
• Aerospace‑Grade Qualification: Tested to rigorous vibration, shock, and acceleration standards.
• High Insulation Resistance: ≥5000 MΩ at room temperature ensures excellent signal isolation.
• Low Pressure Capability: Qualified to 4.4 kPa for high-altitude applications.
• Multiple Configurations: Plug and receptacle available with pin or socket contacts.

Custom Design

The YF8‑42 platform can be adapted to meet unique mission requirements:

• Custom Contact Mix: All 22# contacts standard; other sizes/types available on request.
• Separation Force Adjustment: Modify the breakaway force for specific release requirements (other ranges available).
• Special Materials: Select shell finishes for enhanced corrosion resistance or specific conductivity.
• Cable Assembly Integration: Complete harness solutions with crimped contacts and overmolding.
• Extended Temperature Versions: Higher temperature ratings available on request.
• Non‑Standard Testing: Additional screening for high‑reliability programs.

Why Choose MXTD

At MXTD, we specialize in separation connectors that push the boundaries of density and thermal performance. The YF8‑42 series exemplifies our engineering excellence—packaging 42 signal circuits into a compact, breakaway interface with an extended temperature range of -65 °C to +200 °C, surpassing standard military specifications. Manufactured under strict enterprise standard Q/21EJ1292, each YF8‑42 undergoes comprehensive testing including separation force verification, contact resistance measurement, and dynamic stress screening across its full temperature range. Our team brings decades of experience in separation systems, working closely with customers to ensure that every interface meets the unique demands of the mission—especially when thermal extremes are a concern. When you choose MXTD, you're partnering with a dedicated team focused on the success of your program, from prototype to production.

FAQ

Q: What makes the YF8‑42 unique among separation connectors?
A: It combines ultra‑high density (42 contacts) with an extended temperature range of -65 °C to +200 °C—ideal for extreme thermal environments like engine-adjacent areas or deep‑space applications.

Q: What is the separation force range?
A: The mechanical separation force is calibrated to <80 N, ensuring reliable release while maintaining secure retention during operation.

Q: How many contacts are there, and what are their ratings?
A: 42 contacts total, all size‑22#, each rated at 5 A with a maximum contact resistance of 12 mΩ.

Q: What termination method does this series use?
A: Termination is via crimp for all contacts, providing reliable, production‑friendly connections.

Q: What is the operating temperature range?
A: The connector operates from -65°C to +200°C—wider than the standard -55°C to +125°C range.

Q: What vibration and shock levels can it withstand?
A: It withstands random vibration of 0.3 g²/Hz, shock of 20 g, and constant acceleration of 490 m/s².

Q: What is the dielectric withstanding voltage?
A: 1300 V AC rms at sea level, 500 V under damp heat, and 300 V at low pressure (4.4 kPa).

Q: What is the insulation resistance at room temperature?
A: ≥5000 MΩ—exceptionally high for signal isolation.

Q: What is the difference between YF8‑42TK and YF8‑42ZJ?
A: YF8‑42TK is the plug (cable‑attached half) with socket contacts; YF8‑42ZJ is the receptacle (panel‑mount half) with pin contacts.

Q: Do you provide mating connectors?
A: Yes, both plug and receptacle versions are available. Please specify your configuration when ordering.

Contact Us

Ready to integrate a high‑density separation connector with extended temperature capability into your aerospace or defense system? Our technical experts are standing by to discuss your specific application requirements and recommend the optimal YF8‑42 configuration—from contact arrangement to separation force and termination options.

Whether you need standard units for immediate deployment or custom‑engineered solutions for next‑generation systems, we're here to help you achieve your mission objectives.

Reach out to our team today: manager04@mxtdinfo.com

Let us show you how our YF8‑42 series separation connectors can deliver reliable signal performance in even the most thermally demanding environments.