Modeling and verification of storage reliability of G100 silicone rubber insulation part for electrical connector

doi:10.3785/j.issn.1006-754X.2025.05.133

Chinese Journal of Engineering Design

2025, Vol. 32

Issue (4): 514-522 DOI: 10.3785/j.issn.1006-754X.2025.05.133

Reliability and Quality Design

Modeling and verification of storage reliability of G100 silicone rubber insulation part for electrical connector

Ping QIAN¹,Jiayu SHI¹,Wenhua CHEN¹,Fan YANG²,Youwei WANG¹

^1.National and Local Joint Engineering Research Center for Reliability Analysis and Testing of Electromechanical Products, Zhejiang Sci-Tech University, Hangzhou 310018, China
^2.College of Engineering, Huzhou University, Huzhou 313000, China

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Abstract

Focusing on the reliability modeling of G100 silicone rubber insulation parts for electrical connector under long-term storage conditions, this study analyzed and revealed at the microscopic level that the primary cause of insulation resistance degradation was the oxidation and hydrolysis reactions of polymeric molecular groups in the material matrix induced by environmental temperature and humidity. Based on molecular dynamics and the law of mass action, the change of the carrier concentration of G100 silicone rubber under the effect of temperature and humidity was analyzed, and a physical model for the failure of G100 silicone rubber was established. By applying the central limit theorem, a storage reliability model for G100 silicone rubber insulation part was constructed. The validity and rationality of the constructed model were verified through A-D (Anderson-Darling) and goodness-of-fit tests, supported by scanning electron microscopy and Fourier-transform infrared spectroscopy. The research results provide a theoretical foundation for evaluating the insulation reliability of G100 silicone rubber for electrical connector under long-term storage conditions.

Key words： insulation part for electrical connector G100 silicone rubber failure physics model reliability assessment

Received: 23 April 2025 Published: 01 September 2025

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Cite this article:

Ping QIAN,Jiayu SHI,Wenhua CHEN,Fan YANG,Youwei WANG. Modeling and verification of storage reliability of G100 silicone rubber insulation part for electrical connector. Chinese Journal of Engineering Design, 2025, 32(4): 514-522.

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https://www.zjujournals.com/gcsjxb/10.3785/j.issn.1006-754X.2025.05.133 OR https://www.zjujournals.com/gcsjxb/Y2025/V32/I4/514

电连接器用G100硅橡胶绝缘件贮存可靠性建模与验证

针对电连接器用G100硅橡胶绝缘件在长期贮存条件下的可靠性建模问题，从微观层面分析并揭示了其绝缘电阻下降的主要原因是环境温度和湿度引起了材料基体大分子基团发生氧化和水解反应；基于分子动力学和质量作用定律，分析了在温度和湿度影响下G100硅橡胶载流子浓度的变化，建立了G100硅橡胶失效物理模型；结合中心极限定理，构建了G100硅橡胶绝缘件贮存可靠性模型；利用A-D（Anderson-Darling）检验法和拟合优度检验法，结合扫描电镜和傅里叶变换红外光谱仪，验证了所构建模型的正确性和合理性。研究结果为电连接器用G100硅橡胶在长贮条件下的绝缘可靠性评估提供了理论基础。

关键词： 电连接器绝缘件, G100硅橡胶, 失效物理模型, 可靠性评估

Fig.1 Structure of socket for a certain type of electrical connector

Fig.2 Schematic diagram of G100 silicone rubber insulation part

Fig.3 Schematic of microscopic mechanism of ionic conductance

Table 1 Performance degradation test scheme of G100 silicone rubber insulation part

Fig.4 Test sample of G100 silicone rubber insulation part

技术参数	测量范围
电压测试区间	1~1 000 V
电流测试区间	输入内阻为10 kΩ时，0.1~1 mA；输入内阻为1 MΩ时，1~100 nA
电阻测试区间	1 $×$ 10⁵~1 $×$ 10¹³ Ω
电压精度	电压≥10 V时，(1%±1) V；电压<10 V时，(10%±0.1) V
电流	10 mA
电阻精度	电压≥10 V且电流>10 nA时，±2%；电压<10 V且电流≤10 nA时，±5%
测试速度	快速：测量间隔≤30 ms；慢速：测量间隔≤60 ms

Table 2 Technical parameters of insulation resistance tester

Fig.5 Performance degradation test results of G100 silicone rubber insulation part

待估参数	估计值	待估参数	估计值
$r 0 / T Ω$	1.495	$μ Λ C O 2$	-3.98×10^-3
$σ Λ C O 2$	5.44×10²	$μ Λ$	9.97×10⁴
$σ Λ$	3.13×10³

Table 3 Estimated parameter values

Table 4 Test results of degradation rate of insulation resistance

应力水平组合	$R 2$
75 ℃，72%	0.964
65 ℃，96%	0.971
55 ℃，84%	0.956
65 ℃，84%	0.966
75 ℃，96%	0.955
55 ℃，72%	0.950

Table 5 Determination coefficient of regression model

Fig.6 Surface microtopography of G100 silicone rubber insulation part

Fig.7 Infrared spectrum of G100 silicone rubber before and after aging test


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[[21]]	本文链接：钱萍, 施佳煜, 陈文华, 等. 电连接器用G100硅橡胶绝缘件贮存可靠性建模与验证[J]. 工程设计学报, 2025, 32(4): 514-522. doi:10.3785/j.issn.1006-754X.2025.05.133 doi: 10.3785/j.issn.1006-754X.2025.05.133

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