YF8-4ZJ or TK Separation (Breakaway) Electrical Connector

YF8-4ZJ/TK Separation (Breakaway) Electrical Connector | Lightweight <45g with Integral Wires

The YF8-4ZJ/TK Separation Connector series combines extreme lightweight design with integral wiring to meet the demanding requirements of modern aerospace and defense systems. Weighing less than 45 grams with attached leads, these connectors eliminate the need for field wiring, reducing installation time and potential failure points. Designed for mechanical separation applications, the YF8 series delivers reliable disconnect forces between 10N and 16N while withstanding severe vibration, shock, and acceleration. Whether used in spacecraft deployment mechanisms, missile systems, or unmanned vehicles, the YF8-4ZJ/TK provides the perfect balance of minimal mass and maximum reliability for mission-critical separation events.

Product Descriptions from the Supplier

The YF8-4ZJ/TK Separation (Breakaway) Electrical Connector is a precision‑engineered interconnect solution specifically designed for applications requiring reliable electrical disconnection combined with minimal mass. Fully compliant with enterprise standard Q/21EJ275, this connector series features integral wiring—eliminating the need for separate cable assembly and reducing overall system weight to less than 45 grams. The mechanical separation mechanism is calibrated to release with a force of 10–16 N, ensuring positive separation under commanded conditions while preventing inadvertent disconnect during handling or operation.

Housing four 20# contacts rated at 5 A each with a maximum contact resistance of 10 mΩ, the YF8 supports signal and low‑power transmission in compact separation interfaces. Its robust construction withstands extreme environments: operating temperature from -55 °C to +125 °C, random vibration of 0.3 G²/Hz (20 Grms), sinusoidal vibration of 150 m/s², shock peaks of 735 m/s², and constant acceleration of 30 g. The connector maintains high insulation resistance (>1000 MΩ at room temperature) and passes rigorous dielectric testing at altitude.

Typical applications include spacecraft stage separation, missile launch interfaces, UAV recovery systems, and naval deployment mechanisms—anywhere a lightweight, pre‑wired, breakaway electrical connection is required. With a mechanical life of 500 mating cycles, the YF8 series is suitable for both ground testing and operational reuse.

Specifications

Applications

• Spacecraft: Stage separation, satellite deployment, solar array release.
• Missile Systems: Launch tube interfaces, control surface deployment.
• Unmanned Aerial Vehicles (UAVs): Recovery parachute activation, wing folding mechanisms.
• Naval Systems: Torpedo launch, buoy deployment.
• Aerospace Ground Equipment: Test fixtures requiring breakaway connections.
• Safety Systems: Emergency disconnect in confined spaces.

Functionality

• Integral Wiring: Pre‑attached leads eliminate field wiring, reduce weight, and improve reliability.
• Controlled Separation Force: Calibrated 10–16 N breakaway ensures positive disconnect without false releases.
• Ultra‑Lightweight: <45 g total mass minimizes impact on system weight budgets.
• Environmental Robustness: Withstands extreme temperature, vibration, shock, and acceleration.
• Four 20# Contacts: Supports signal and low‑power needs in separation interfaces.
• High Insulation Resistance: Maintains signal integrity even after humidity and mechanical stress.

Key Features​​​​​​​

• <45 g Total Mass: Integral wiring and compact design achieve exceptional lightness.
• Pre‑Wired Convenience: Connector ships with attached leads, reducing assembly time and potential failure points.
• Calibrated Separation Force: 10–16 N range ensures reliable operation across diverse mission profiles.
• Aerospace Qualification: Tested to rigorous vibration, shock, and acceleration standards.
• Wide Temperature Range: -55 °C to +125 °C suits both space and airborne applications.
• 500‑Cycle Life: Suitable for ground testing and multiple mission uses.
• Low Contact Resistance: ≤10 mΩ ensures minimal power loss and signal attenuation.

Custom Design

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

• Custom Lead Lengths: Specify wire length and gauge to match system needs.
• Alternative Contact Arrangements: Additional contacts or different contact sizes available on request.
• Special Materials: Select shell finishes for enhanced corrosion resistance or specific conductivity.
• Separation Force Adjustment: Modify mechanism for non‑standard release forces.
• Cable Harness Integration: Combine with other connectors or breakout boxes.
• Non‑Standard Testing: Additional screening or qualification testing for high‑reliability programs.

Why Choose MXTD

At MXTD, we understand that every gram counts in aerospace and defense systems. The YF8-4ZJ/TK separation connector embodies our commitment to lightweight engineering without compromising reliability. By integrating wires directly into the connector, we reduce weight, eliminate assembly steps, and remove potential failure points. Manufactured under strict enterprise standard Q/21EJ275, each YF8 undergoes comprehensive testing—including separation force verification, contact resistance measurement, and environmental stress screening. 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. 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 does "integral wiring" mean?
A: Integral wiring means the connector is supplied with wires already attached and terminated inside the connector. This reduces installation time, eliminates soldering/crimping errors, and minimizes overall weight.

Q: What is the total weight of the connector?
A: The complete connector with integral wires weighs less than 45 grams.

Q: What is the separation force range?
A: The mechanical separation force is calibrated between 10 N and 16 N.

Q: How many contacts are available, and what is their rating?
A: There are four 20# contacts, each rated at 5 A with a maximum contact resistance of 10 mΩ.

Q: What is the operating temperature range?
A: The connector operates from -55°C to +125°C.

Q: Can the connector be reused after separation?
A: Yes, the mechanical life is rated for 500 mating/separation cycles, making it suitable for multiple tests and operational uses.

Q: What vibration and shock levels can it withstand?
A: It withstands random vibration of 0.3 G²/Hz (20 Grms), sinusoidal vibration of 150 m/s², shock of 735 m/s², and constant acceleration of 30 g.

Q: Are custom lead lengths available?
A: Yes, we can customize wire length and gauge to meet your system requirements. Please contact our sales team.

Q: What is the insulation resistance after environmental testing?
A: After humidity and vibration testing, insulation resistance remains ≥20 MΩ, ensuring reliable signal transmission.

Q: Do you provide mating connectors?
A: Yes, both plug and receptacle versions (YF8-4ZJ/TK) are available. Please specify your configuration when ordering.

Contact Us

Ready to lighten your separation interface without sacrificing reliability? Our technical experts are standing by to discuss your specific application requirements and recommend the optimal YF8 configuration—from lead length to contact arrangement.

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 series lightweight separation connectors can reduce system mass and simplify assembly while delivering dependable breakaway performance.