As connectors get smaller, the importance increases. The reason is simple, products are getting smaller. Nowadays, smartphones, tablets, blood glucose detectors and countless other electronic devices have more and more stringent size requirements, and the interior is getting tighter, so there is not much room left for connectors. This trend is also emerging in defense and aerospace, such as in satellites, guided missiles and avionics systems, where compactness requirements can only be met by "miniature" connectors. The demand for smaller connectors is rising, and design engineers are facing a new set of challenges. They can no longer put the design of the connector to the final stage of the project. Miniature connectors require forethought. It requires designers to consider a variety of factors such as packaging, durability, current load capability, and replaceability, and designers should consider replacement convenience connectors.

Consider connectors early in the design

Consider connectors early in the design

Engineers tend to focus too much on designing the overall system and put the connector at the end of the design stage. Think that the connector is simple, so you can put the relevant design at the last stage. And then got stuck with his own design. In many cases, designers end up choosing non-standard connectors to complete the design, which not only drives up costs, but also delays delivery times. In order to avoid such problems, experts recommend that the connectors to be used should be considered early in the design, and then reserve design space for them, and the design should also be carried out around them.

First, decide which connector you need, but if you do do it, you can actually save a lot of time and a lot less trouble.

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 the traces on the PCB board and the additional wires connected to the connectors. Because the spacing becomes smaller, the traces and wires must be narrower.

Also, keep in mind that some connectors, such as flex cable connectors, offer the option to flip forward and backward. These flipping methods need to be considered when designing a system. For example, a backward-flipped connector may be inaccessible if there is another component on the front and back.

Finally, designers also need to be aware that surface mount devices sometimes fail to handle smaller components. In some cases, they need new vacuum nozzles to solve these problems.

Figure out the current load capability

As the size of the connector decreases, so does the current load capacity of the connector. In general, miniature connectors can handle currents between 200mA and 500mA, which is almost half the rated current of larger board-to-board connectors. To compensate for the low current-carrying capacity, designers may need to increase the number of terminals.

Consider the stability of small, miniature connectors

Not only at the design stage, but also during assembly, they are guaranteed not to be damaged. If this is not taken to heart first, it can drive up costs and damaged connectors need to be reconfigured, refurbished, and marked. Even more expensive, field-replaceable connectors may be required, and such changes may extend design time by another week or two.

It should be noted that you should always prioritize existing connectors, and if these connectors are not compatible with the design, consider your own design, which can save a lot of time.

Consider ease of replacement

If the exterior of the product is closed, then a connector that can be replaced from the outside is required. Otherwise, you need to do some welding work. The more you do, the more skilled you will be at skills such as welding, but the higher the risk of damage to the entire system.

Understand the functional requirements for connectors

Suppliers need customers to fully express their needs, otherwise they may misunderstand their needs. This is especially important when custom connectors need to be manufactured. It is critical to accurately articulate the requirements for the connector, and if they are poorly articulated or omissions, critical requirements of the design may be overlooked.

07. Consider mechanical stress

Temperature, shock, and vibration all create stress between the interface and the circuit. Experts recommend that you choose connectors that avoid these forces. When a connector is securely attached to a board or outer structure, it must be able to withstand the forces of shock and vibration, otherwise cracks may occur. It is recommended that engineers use interconnect systems to minimize the accumulated stress between the mounting structure and the connection points. There are many vendors that offer such systems. Designers should pay close attention to this.