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Connectors for Printed Electronics
1.
1© Copyright 2011
NICOMATIC. All rights reserved. SGIA Interconnect Solutions for Printed Electronics
2.
2© Copyright 2011
NICOMATIC. All rights reserved. Introduction ! Topics: – Types of connectors available for printed electronics manufacturers – Connector challenges facing various industries ! Industries covered: – Membrane Switches " LIF/ZIF " Crimp – Printed Sensors – Medical Sensors – Lighting – Wearables
3.
3© Copyright 2011
NICOMATIC. All rights reserved. Membrane Switches ! User interface that uses pressure to open and close a circuit ! Common applications include: – Industrial control panels – Medical equipment – White goods – Fitness equipment control panels ! Interconnect options: – ZIF/LIF – Crimped contacts
4.
4© Copyright 2011
NICOMATIC. All rights reserved. LIF/ZIF Connections ! Advantages – Large number of available pitches " 0.25 mm up to 2.54 mm " Higher density contacts – Low cost – Low profile ! Manufacturers – Molex – AMP – JST – Samtec – HRS – Omron
5.
5© Copyright 2011
NICOMATIC. All rights reserved. ZIF/LIF Features ! Features – Insertion force " ZIF: Zero Insertion Force " LIF: Low Insertion Force – Tail stiffener " Keeps contacts in place for termination " 0.3 mm or 0.2 mm – Contact location " Top, bottom or dual – Plating options " Tin and gold • Gold only for <0.5 mm pitch – Retention features " ZIF requires actuator to retain cable • Top flip or slide types " Locking tabs for more security – Shielding " Similar to Hirose FH41
6.
6© Copyright 2011
NICOMATIC. All rights reserved. Membrane Switches: Crimp ! Advantages – High retention strength – Higher reliability – Exposed ink not required – Wider variety of mating options ! Available pitches – 2.54 mm (0.100”) – 2.00 mm (0.079”) " No male pin. Female or solder tab only – 1.27 mm (0.050”) " No male pin. Female or solder tab only ! Manufacturers – Nicomatic CrimpFlex™ – FCI Berg – Tyco – Molex
7.
7© Copyright 2011
NICOMATIC. All rights reserved. Membrane Switches: Crimp Contacts ! Contacts available in tin and gold plated ! Female contacts can be low insertion force or high insertion force Three Basic Styles Market Picture Mates to Receptacle (Female) 90% Square pin Pin (Square Male) 8% Female Soldertab (Male) 2% PCB, socket
8.
8© Copyright 2011
NICOMATIC. All rights reserved. Basic Styles MarketPicture Mates to Standard, Stackable75% Non-Stackable Polarized, not locking5% Detent 2%% Latching 18% Membrane Switches: Crimp Housing Types
9.
9© Copyright 2011
NICOMATIC. All rights reserved. Printed Sensors and Heaters ! Types of sensors include: – Photodetectors – Temperature sensors – Humidity sensors – Gas detectors – Pressure sensors ! Manufactured with ink-jet printing, gravure printing, screen printing or flexography
10.
10© Copyright 2011
NICOMATIC. All rights reserved. 10067 10141 1016710241 11612 12887 Printed Sensors: Soldertab Contacts ! Soldered directly onto PCB or inserted into IC socket
11.
11© Copyright 2011
NICOMATIC. All rights reserved. Staple/Butt Crimp ! Attach two Flat Conductor Material – Printed ink/Printed Ink – Printed Ink/FFC – Printed ink to FPC ! Staple Crimp – Two overlapping materials are ‘Stapled’ together with a crimp contact ! Butt Crimp – Two materials assembled end to end with half of crimp contact on each material
12.
12© Copyright 2011
NICOMATIC. All rights reserved. Disposable Medical Sensors ! Disposability allows for greater sterility by reducing contact between patients. ! Common disposable medical devices include: – Temperature probes – Blood pressure sensors – ECG electrodes ! Available solutions – High flexibility crimp contacts allow for high number of mating cycles – Flat and light latched housing can provide high retention force with easy connection and disconnection
13.
13© Copyright 2011
NICOMATIC. All rights reserved. Medical Sensor Requirements ! Signal integrity for robust transmission of critical data – Need for shielded connectors ! Chemical compatibility can be critical – Especially when medical gels are packaged with materials ! Housings must be able to withstand sterilization processes
14.
14© Copyright 2011
NICOMATIC. All rights reserved. Medical Sensors Industry Challenges ! Reliability of the solution in harsh environments " Numerous cycles of use, vibrations, etc. " Female contact on sensor " Male pin on mating part for increased life – Miniaturization " Increase density and portability – Ease of mating and unmating ability " Low insertion force/high retention force " May require custom solutions – Capability to prove the system " Prototype stages can be prolonged due to regulatory requirements
15.
15© Copyright 2011
NICOMATIC. All rights reserved. Lighting Industry ! Examples of applications include: – Strip lighting – Under shelf lighting – EL lamp applications – Safety lighting – Automotive lighting – Marine lighting – Aerospace lighting ! Frequently looking for transition to discrete wire. ! All connectors discussed in this presentation are used but flat to discreet wire connections are commonly seen.
16.
16© Copyright 2011
NICOMATIC. All rights reserved. Crimp to Discrete Wire Connector ! Detachable – Typically latching connectors – 22-28 AWG – 2.54 mm and 2.00 mm pitch ! Permanent – Lower profile – Non-removable – 2.54 mm pitch
17.
17© Copyright 2011
NICOMATIC. All rights reserved. Wearable Market ! Strong emerging market ! Potential applications include: – Sensors built into clothing – Smart Watches – Smart Glasses – Headsets – Fitness, heartrate and blood pressure monitors – Insulin pumps
18.
18© Copyright 2011
NICOMATIC. All rights reserved. Examples of Wearable Connectors ! Snap connector – Similar to clothing snaps – Multiple connections are a challenge for this industry ! Crimp – Can be integrated with conductive textiles ! Custom solutions – Ease of mating and unmating – Collaboration between designers and OEMs is critical and new connectors being developed for this growing market.
19.
19© Copyright 2011
NICOMATIC. All rights reserved. Other Interconnect Options ! Many other options still in conceptual phase ! RJ-45 and USB – Commonly used for networking – Good potential for controller-sensors connection
20.
20© Copyright 2011
NICOMATIC. All rights reserved. 2.00 mm Pitch Crimp ! Compatible with flat conductors including printed ink ! 2.00 mm (0.079”) Up to 60% space saving over 2.54 mm pitch ! PCB, SMT, and cable mating options – Flat or right angle ! Military-grade housings – Stainless steel – Available with locking mechanisms " Latches " Thumbscrews " Guide pins
21.
21© Copyright 2011
NICOMATIC. All rights reserved. Waterproof Connectors ! Commonly used in marine industry ! IP67 or IP 68 certification ! Top: Sealed box design – 2 part crimp ! Bottom: Clamshell design – Rim has waterproof gasket
22.
22© Copyright 2011
NICOMATIC. All rights reserved. Conclusion ! Best interconnect solution depends on application and requirements ! Options include: – ZIF/LIF " Large number of available pitches " Low cost " Low profile – Crimp " High retention strength " Higher reliability " Exposed ink not required " Wider variety of mating options " Can staple or butt crimp – Many custom solutions are also available
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