Nowadays, countless electronic devices such as smartphones, tablets, blood glucose monitors, etc. have stricter and stricter size requirements, and the interior is getting tighter and tighter, so there is not much space left for connectors. So the smaller the connector becomes, the more important it becomes. This trend is also seen in the defense and aerospace fields, such as in satellites, guided missiles, and avionics systems, where compactness requirements can only be met by "miniature" connectors. As the demand for smaller connectors continues to rise, design engineers face a new set of challenges. They can no longer put the connector design into the final stages of the project. Micro connectors require forethought. It requires designers to anticipate a variety of factors such as packaging, durability, current-carrying capability, and replaceability.
Seven directions of miniature connector design
1. Consider connectors early in the design
"Engineers tend to be so focused on designing the overall system that they put the connector at the very end of the design," said Mitch, our director of product development engineering. "They think the connector is simple, so they can put the To the final stage. Then they get stuck with their own design.” He has seen too many stories of designers rushing to design connectors in the final stages of design. He told us that in many cases, designers end up having to choose non-standard connectors to complete the design, which not only drives up costs but also delays delivery times. In order to avoid such problems, relevant experts recommend that you should consider the connectors you will use early in the design, and then reserve design space for them and design around them. "There's no reason for you to say 'First, decide which connector you need,'" said Morley, our product development engineer, "but if they did, it would actually save them a lot of time and a lot of hassle."
2. Understand the limitations of space
Although miniature board-to-board connectors are typically less than 1 mm thick, they are also commonly used in tightly packed applications. To address potential packaging issues, designers need to consider circuit traces on the PCB, as well as additional wires connected to the connectors. "Because of the smaller pitch, you have to make the traces and wires narrower," said Mike Higashikawa, Molex area product manager. Also, keep in mind that some connectors (eg: flex cable connectors) offer the option to flip forward and backward. You need to consider these flipping methods when designing your system. For example, a connector that is flipped back may be difficult to access if there is another component on the front and back. Finally, designers also need to be aware that surface mount devices sometimes cannot handle smaller components. In some cases, they need new vacuum nozzles to solve these problems.
3. Find out the current load capacity
As connector size decreases, so do the current carrying capacity of the connector. Typically, micro connectors can handle between 200mA and 500mA, which is roughly half the current rating of larger board-to-board connectors. To compensate for the lower current-carrying capacity, designers may need to increase the number of terminals.
4. Consider the stability of small/micro connections
"I need to advise on this, not only at the design stage but also during the assembly process to keep them safe from damage." Morley, an expert in micro connector design in RF applications, recalls that in his design of military, In space applications, half of the connectors were destroyed during the testing phase.
Failure to take the issue to heart in the first place could drive up costs, he said. Damaged connectors require reconfiguration, refurbishment, and marking. There may even be a need for more expensive, field-replaceable connectors to replace, and such a change could add another week or two to the design time.
"It should be noted that always prioritize existing connectors, and if those connectors are not compatible with your design, consider designing your own, which can save you a lot of time," Morley said.
5. Consider easy replacement
If the exterior of the product is closed, then you need connectors that can be replaced from the outside. Otherwise, you'll need to do some soldering work.
"The more you do it, the more skilled you are at skills like welding, but the higher the risk of damage to the entire system," Morley said.
6. Understand the functional requirements of the connector
Suppliers need customers to fully express their needs, otherwise, they may misunderstand customer needs. This is especially important when custom connectors need to be manufactured.
"Accurately articulating the connector's requirements is critical," says Story. "If it's unclear or omitted, we risk missing key requirements for the design."
7. Consider mechanical stress
Temperature, shock, and vibration all create stress between interfaces and circuits. Experts suggest that you should choose connectors that avoid the effects of these forces.
"I've seen solder joints that have broken into pieces on some PCB boards," Morley said. "When a connector is firmly attached to the board or outer structure, it has to withstand the forces of shock and vibration, otherwise it will There may be cracks."
Morley recommends that engineers use an interconnected system to minimize the build-up of stress between the mounting structure and connection points. "There are a number of suppliers that offer such systems," he said. "Designers should pay close attention to this."
pogopin connector manufacturers supply - Shenzhen ZZT Precision Electronics Co., Ltd.
Founded in 2007, it is a high-tech enterprise with precision connection as the leading factor and technology development as the core, integrating R&D, production, and sales. Our main products are POGO PIN, POGO PIN connector, magnetic connector, magnetic charging data cable, and adsorption connector. Our products are widely used in smart wear, mobile communications, digital cameras, automobiles, medical equipment, and other fields.
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