The document discusses various interconnect solutions for printed electronics manufacturers across different industries. It provides details on membrane switch connectors using low/zero insertion force connections or crimped contacts. It also covers printed sensors, medical sensors, lighting applications, and emerging areas like wearables. Connector types discussed include ZIF/LIF, crimp, solder tabs, and custom solutions. Key requirements addressed are reliability, miniaturization, and ease of mating for applications like medical sensors.

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

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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

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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

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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

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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

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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

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Basic Styles MarketPicture Mates to
Standard, Stackable75%
Non-Stackable
Polarized, not locking5%
Detent 2%%
Latching 18%
Membrane Switches: Crimp Housing Types

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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

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10067
10141
1016710241
11612 12887
Printed Sensors: Soldertab Contacts
! Soldered directly onto
PCB or inserted into IC
socket

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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

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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

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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

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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

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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.

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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

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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

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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.

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Other Interconnect Options
! Many other options still in
conceptual phase
! RJ-45 and USB
– Commonly used for networking
– Good potential for controller-sensors
connection

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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

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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