Connectors for Printed Electronics

1© Copyright 2011 NICOMATIC. All rights reserved.
SGIA
Interconnect Solutions for Printed Electronics

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

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

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

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

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

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

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

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

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

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

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

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

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

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.

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

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

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.

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

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

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

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

Connectors for Printed Electronics

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Connectors for Printed Electronics