Join us for this panel webinar, in which industry experts will provide insight on selecting, specifying and using miniature connectors safely and reliably in your system designs. Our panelists include David Ptacek, national sales manager and US product manager for Fischer Connectors’ MiniMax series; Steven Lassen, Products and Applications Manager, LEMO USA; Mike Higashikawa, Regional Product Manager, Micro Products Division for Molex Incorporated; and Brendan Dempsey, Business Development Manager at ODU-USA. Our panel will discuss some of the challenges and misconceptions associated with miniature connectors, covering everything from EMI/EMC to robustness and mating reliability to common applications.

1. Key Considerations When
Switching to Miniature
Connectors

2. q This webinar will be available afterwards at
www.designworldonline.com & email
q Q&A at the end of the presentation
q Hashtag for this webinar: #DWwebinar
Before We Start

3. Moderator
Mary Gannon
Design World
Steven Lassen
LEMO USA
David Ptacek
Fischer Connectors’
MiniMax Series
Mike Higashikawa
Molex Incorporated
Brendan Dempsey
ODU-USA

4. Miniaturization of Connectors – Biggest Push -­‐‑ Markets
Medical
Catheters
Handpieces
Military
UAVs
Soldier-­‐‑worn

5. Connector Miniaturization – Consolidating Connectors
Hybrids
Fluidic /
Pneumatic
Coax
Fiber
Optic

7. MILITARY INTEGRATED SOLUTIONS
ODU AMC® - Advanced Military Connectors
§ Push-Pull locking or Break-Away function
§ Easy-Clean version with spring loaded contacts for fast and easy
cleaning at the battle field
§ Extremely robust and rugged
§ Light weight, small and easy handling (blind mating)
§ Color keying, optimized mechanical keying
§ Excellent shielding features: 360°
§ Water tight - Protection class IP68
§ Excellent data transmission
§ Individual contact configuration: signals, low/high voltage
§ transmission, coax/ triax, fiber optic, compressed air and fluid
§ Inserts are possible in one connector
§ Long service life up to 5,000 mating cycles
§ Operating temperature range from -55°C up to +125°C
§ System solution incl. cable assembly and over molding
§ version for mating under load possible

8. Miniaturization in the
Military
“Maintaining a lightweight design is extremely important
when dealing with portable units. Some connectors
provide a weight savings of up to 75% compared to
standard connectors.”
-­‐‑ Wim Vanheertum,
Product Manager
Fischer Connectors SA

9. Miniaturization in the
Military
Considerations include making
sure the miniature connector is not
so small or difficult to use that
soldiers can’t manage to connect or
disconnect when wearing gloves.

10. DS
9808
Medical
Military, Industrial

11. Miniaturization in Medical
Smaller, more portable devices,
along with an increase in body-­‐‑
worn medical devices, drives
demand for miniature and/or
multi-­‐‑functional connector
solutions.

12. Miniaturization in
Instrumentation
Sealing to IP68 is a challenge when it
comes to miniature connectors, but it
can be done, allowing even the most
sensitive instruments to remain
accurate in extreme conditions.

13. Fischer MiniMax™ Series
19 pins Mixed Signal + Power
5,000 Mating cycles
Fischer UltiMate™ Series 07
10 pins
10,000 Mating Cycles

19. PRODUCT FEATURES:
§ 2 – 40 poles
§ 4 sizes
§ Watertight protection class IP 68
§ Lifetime of greater than 5,000 mating cycles
§ Break-­‐‑Away for maximum safety
§ Extremely robust and stable housing with non-­‐‑
reflecting surface
§ Operating temperature range from -­‐‑51° C (-­‐‑60°
F) to +125° C (+257° F)
§ Contacts for solder and PCB termination
§ Light, compact and easy to use – blind mating is
also possible
§ Highspeed data technology
§ Diameter of less than 10 mm to 18.5 mm
§ Contact density of up to 40 contacts
§ Includes versions for: Power (up to 15 A) & Data Transfer
(USB 3.0 with 5A power)
§ Maximum operating reliability thanks to mechanical keying
and visual colour coding
§ Versatile and individually configurable: Signal, power and
data possible within one connector
§ Salt spray resistance
§ 360° shielding for excellent, trouble-­‐‑free data transfer
§ Connection to flex or printed circuit board solutions on the
receptacle side
§ Termination to PC-­‐‑boards, flex-­‐‑layers or rigid-­‐‑flex solutions
§ Innovative options for assembly and extrusion for the cable
bend relief
ODU AMC® HIGH-DENSITY

20. ODU AMC® HIGH-DENSITY

21. ODU AMC® HIGH-DENSITY
ONE PC BOARD FITS ALL SIZES:

22. Miniaturization of Connectors – Which Connector to Use?
Indoor
Environmental
Medical

23. Miniaturization Challenges
• .
Challenge
Action
Miniature connectors aren’t rugged enough for
application, or cannot be sealed to IP
specifications
Keep looking. There are companies that specialize in rugged
miniature connectors that can withstand extreme environments and/
or frequent connects and disconnects.
Sourcing the right cable for a dense connector
solution that is multi-­‐‑functional.
Check with your connector partner to get cable recommendations.
Look for an authorized assembly house to help.
Right-­‐‑sizing: Sometimes a connector can be too
small to be practical for its intended use.
Be sure to field test with gloves if necessary before commioing to a
connector.
Integrating signal and data into a miniature
connector may lead to electrical interference.
Make sure you are working with companies that understand
shielding and how it works in miniature connectors.

24. Miniaturization of Connectors – Challenges
Skilled Assembly
Sourcing Miniature and Technical Cable

25. Miniaturization of Connectors – Design Considerations
Electrical Requirements
• Current (conductor AWG)
• Voltage (Creepage & Clearance)
• Shielding
Material Requirements
• Metal or Plastic
• Non-­‐‑magnetic
• Environmental Resistance
Data Transfer Rates
• Ethernet
• USB
• RF (coax)
• Fiber Optic

26. Cable Configurations
When it comes to miniaturization, choose your cable wisely

27. ODU AMC® HIGH-DENSITY
HIGHSPEED AND DATA TRANSMISSION:

28. ODU AMC® HIGH-DENSITY
TERMINATION PC-­‐‑BOARD:

29. Miniaturization of Connectors – EMI / EMC Impact
Less material = Less shielding
• Multiple sleeves
Smaller = BeDer for RF
• At higher frequencies

30. ODU AMC®- PROCTECTIVE CAPS
AMC® caps provide water, sand, dust protection and
EMI protection for equipment up to 60db.
§ For plugs Break-­‐‑Away and Push-­‐‑Pull
§ For receptacle G8
§ For receptacle GK and in-­‐‑line receptacle

31. Miniaturization of Connectors – True Costs
Connector Size
Material costs
Weight
Machining tolerance
Skilled Labor
Assembly Time
Custom Cable

32. Lower Your
Total Cost of Ownership
A well-­‐‑chosen miniature, dense
connector can replace more
than one standard connector,
saving space on the device,
investment in materials, and
even make a beoer end user
experience.

33. Robustness & Reliability – Basic Building Blocks

34. Robustness & Reliability – Ruggedizing / Customizing

35. ODU AMC® HIGH-DENSITY
RELIABLE AND ROBUST CODING:

36. Complete Military Solution System
Cable assembly: over molding or boots

37. ODU AMC® & ODU AMC® HIGH-DENSITY

38. Questions?
Mary Gannon
Design World
mgannon@wtwhmedia.com
Mike Higashikawa
Molex Incorporated
Mike.higashikawa@molex.com
Brendan Dempsey
ODU USA
Brendan.dempsey@odu-usa.com
David Ptacek
Fischer Connectors
David.ptacek@fischerconnectors.com
Steven Lassen
LEMO
slassen@lemo.com

39. Thank You
q This webinar will be available at
designworldonline.com & email
q Tweet with hashtag #DWwebinar
q Connect with Design World
q Discuss this on EngineeringExchange.com