The connection is critical
In high-stakes environments, whether it is a fighter jet fuselage, a naval radar system, or high-end industrial automation, signal integrity is not a luxury. It is a necessity.
For design engineers, the challenge is rarely just the connector (or cable) itself. The vulnerability usually lies in the termination, specifically the point where the cable shield meets the backshell. If this interface fails under vibration or allows EMI leakage, the entire system's reliability is compromised.
At KEC, we believe that specifying the right backshell shouldn't be an afterthought. We have compiled this checklist to help you navigate the complexities of EMC protection and ensure your interconnect solution performs as well as the rest of your design.
1. The 360° shielding rule
The most common cause of EMI failure is "gapping"(or ‘’holes’’) in the screen termination.
The problem: Standard clamping methods often leave small gaps (or windows) in the shielding coverage, creating "leakage points" for high-frequency noise.
The solution: You must specify a backshell that guarantees 360° screening continuity.
The KEC approach: Look for systems that utilise a continuous (360 degree) spring mechanism - such as our KC Series with IRIS spring technology - rather than intermittent pressure points. This ensures low-resistance electrical contact around the entire circumference of the cable braid, eliminating the gaps where interference can penetrate.
2. Vibration and shock resistance
Aerospace and defence applications subject components to intense G-forces. A backshell that tests well on a static bench may fail in the field if the design is not robust.
Key questions for your specification:
If the screen termination bears the mechanical load of the cable, movement will eventually degrade the electrical contact. Ensure your backshell (termination system incorporates) these functions. Ideally, you want one mechanism for electrical continuity (like the IRIS spring) and a (an additional) for mechanical strain relief (like a cable clamp or heat shrink boot).
3. Environmental sealing and galvanic corrosion
It is not only about the electronics, but also about chemistry. When dissimilar metals meet in a saline or humid environment, galvanic corrosion can destroy your shielding effectiveness within months.
The checklist:
4. Ease of assembly (the hidden cost)
As a project manager or production engineer will tell you, the cost of the part is only half the equation. The cost of installation is the other.
Many high-performance backshells require expensive, proprietary tooling to install. This adds capital cost and complicates field repairs.
The KEC advantage: We engineer our backshells to be installed with standard hand tools. Our unique wire spring technology allows for a secure, reworkable connection without the need for calibrated crimp tools or banding straps. This simplifies the supply chain and speeds up production. (One of our main design criteria is ease of assembly and reworkability)
5. Standard vs custom: knowing when to pivot
The final consideration is geometry (fit).
Sometimes, a standard straight or 90° backshell simply will not fit within the spatial (size) envelope of a retrofit or a compact new design.
Don't force a fit. If the catalogue part requires you to compromise on cable routing or bend radii, it is often more cost-effective to commission a modified or bespoke design. Because we manufacture in the UK, KEC can modify existing designs or create entirely new geometries with short lead times. This ensures your interconnect solution fits your reality, not just a datasheet.
Summary: Secure your signal
The difference between a reliable system and a compromised one often comes down to the quality of the termination. By prioritising 360° shielding, vibration resistance, and ease of assembly, you ensure your project meets its performance targets.
Need help specifying your next project? Don't rely on guesswork. Speak to our engineering team about your specific requirements.
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