The Hidden World of Miniature Connectors

Miniature connectors are utilized in various applications today, particularly in cases where weight, power, and size are the main requirements for designs. Today, there’s hardly any industry that doesn’t require equipment to get lighter, more functional, and smaller. According to Moore’s law, miniaturization of devices and electronic components means moving and replacing bulky devices with mobile versions.

Basically, miniature connectors are required for handheld, body-worn, and portable applications, especially in cases that require light and limited weight. Examples of industries with these applications include testing equipment, instrumentation, civil or military unmanned aerial vehicles, defense and security, and some medical equipment.

In this article, we will explore the fascinating realm of tiny connectors, especially those used in compact devices and wearables. Continue reading for more.

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What Miniature Connectors are Inside Compact and Tiny Wearables?

Wearable devices are getting smaller by the day, and their small size, smooth function, and organic lines are super impressive. But what are the connectors and components within these devices? We will have a quick look at these connectors below. They include the following:

Flexible Printed Circuits

Due to the compact size of wearables, there’s a need to integrate sensors that interact with the body with ultra-tiny electronic processors before packaging them into small devices. The only way to achieve this is through the use of flexible printed circuits (FPCs). Today, FPCs are a secret weapon for many reasons. This includes the fact that they are easier to assemble and cheaper, and they enhance the compact wrapping of circuits in 3D forms. Also, FPCs help to keep components and circuits confined in a 2D tape.

An example of FPC use can be seen in Google’s Pixel Buds 2 as the device include microphones, speaker, Bluetooth circuit, antenna, and battery, all of which are compact into a 5g device.

Making Connections

Regardless of how compact the wearable device may be, it will need to connect effectively with the outside world. There are so many connectors placed within these devices, and we’ll highlight some of them. They include the following:

Pogo Pin Connector: This is a reversible way of connecting wearables to exterior components. Basically, these connectors can be disconnected and reconnected multiple times without getting damaged. This type of connector is the ideal option for devices that are repeatedly connected to things like a charger.
Board-To-Board Connector: They are used to connect rigid boards to flexible printed circuits, especially in cases that require transmission of a lot of signals. They usually have so many pins which enhances connection. These connectors are generally more applicable and affordable than FPCs.
Zero Insertion Force Connectors: These connectors are designed to un-mate and mate. Basically, they are the ideal option for components that are connected, but they are unattached in the assembly process.
Hot Bar Soldering: Hot bar soldering is also used to connect components, and it’s an affordable option. However, it’s not easy to disassemble connected devices without unsoldering the joint.
U.FL Coaxial Connectors: This connector allows for the transmission of signals from radio frequency antenna to digital circuit boards. Basically, U.FL coaxial connectors provide a covering on the interface to facilitate the conversion of analog signals to digital signals. This technology is common in Apply AirPods.
Lase it Direct: This is a cool manufacturing process that is applied in many wearables. It’s also called laser direct structuring and it’s a unique process. The technique is used in incorporating antennas directly to the device shell without taking much interior space.

Development Trend of Miniature Connectors Technology

Connectors have long been an obstacle when it comes to improving the surface installation rate of electronic components. However, SMT equipment, miniature connectors, and manufacturers have made a lot of progress in recent times. Here are some of the development trends of miniature connectors technology that you should know:

Narrow Spacing

The reduction in contact distance is a trend to note, and this allows for the multiplication of the number of contacts per unit area. With that, distance becomes a vital indicator of high-density connector miniaturization.

Thinner

Most recent electronic components now have newer requirements for connectors. This includes getting thinner and reducing their height. Even though it’s easy to decrease connector spacing, the same doesn’t always apply to its height. Connectors are the highest parts on PCB, and with that, a reduction in their height will help in reducing their overall volume.

This makes thinness a key part of the development of miniature components. As development in the field of science and technology continues to advance, low height and thinness of connectors will become a lot easier to achieve.

Low Insertion Force

Miniature connectors are usually closely connected, and this can introduce the problem of a large insertion force. To avoid this problem in miniature connectors, there’s a need for low insertion force and zero insertion force structures. This is becoming increasingly available in miniature connectors because without them, plugging and unplugging the connectors will not be easy to achieve.

Conclusion

The bottom line is that connectors for compact and wearable devices are becoming smaller by the day, and they are also becoming better, especially when it comes to variety and performance. Today, wearables are utilized in various industries for different applications, including military, medical, and a wide range of industrial devices. Another thing to note is that these devices can be applied in environments with different power, size, and weight requirements.

In addition to the size, weight, and power requirements, there are instances where these devices may be subject to harsh operating conditions and strict signal integrity demands. For example, exposure of military connectors to high shock or vibrations, or the sterilization of medical connectors.

A key thing to understand is that the best wearable design depends on the device itself. The shape of the device may support FPCs or not, and the number of units to be featured will also determine the choice of connectors for the device. Laser direct structuring may be required in an instance where there’s a need for a large volume antenna to be packed in a tiny device.