FPC connector (Flexible Printed Circuit Connector) is a kind of electronic connection device designed for flexible printed circuit (FPC). It is usually composed of three parts: the flexible contactor, snap and shell, of which the flexible contactor is the core part of the connector, made of steel, phosphor bronze and other elastic materials; snap is used to fix the position of the FPC connector and the circuit board; the shell plays a role in protecting and fixing.
The basic structure of the FPC connector
1.Base Assembly (Base Assembly)
As a structural foundation and PCB welding fixed, generally made of high-temperature engineering plastics (LCP/PA66), the use of precision injection molding, soldering, feet plating process.
2.Contact system (Contact System)
Core components: phosphor bronze/beryllium copper elastic contacts, surface treatment selection of gold-plated (0.05-0.2μm) or tin-plated, contact resistance ≤ 30mΩ, insertion and removal life ≥ 5000 times.
3.Clamping Mechanism
Composite material with reinforcing structure, quick locking with flip/slide cover, adjustable clamping force: 5- 20N.
4.Auxiliary System
Metallized shell or local shielding layer, high-precision guide column (±0.05mm), asymmetric plug structure.
The structure design of the three technical advantages
Miniaturization: Minimum 0.2mm pitch realized.
High reliability: meets USCAR-2 automotive standards.
Easy maintenance: supports quick plug-and-play operation
Typical application scenarios include: folding screen cell phone pivot area (200,000 times bending), vehicle display (125℃ high temperature resistance), medical endoscope (IP68 protection).
The working principle of FPC connectors
The working principle of FPC connectors is based on the dual role of electrical contact and mechanical locking. When the plug of the FPC connector is docked with the socket end, the internal contact terminals will make electrical contact with the conductive path of the circuit board to realize the transmission of electrical signals. At the same time, the connector's locking device mechanically secures the connector firmly in the socket, avoiding dislodgement due to external vibration or tension.
FPC connectors usually have high contact stability and interference immunity, and therefore perform well in high-speed signal transmission. The number of times a connector can be plugged and unplugged can usually reach thousands of times or even more, ensuring its reliability over a long period.
The role of FPC connectors
1.Precision interconnection function
Realize the reliable connection between the flexible circuit board (FPC) and PCB board, at the same time to complete the mechanical fixation and electrical conduction dual function, support a variety of connection methods (board to board, wire to board, FPC to FPC).
2.System stability guarantee
Multi-point contact design to ensure the reliability of the connection, to prevent poor contact due to vibration or temperature changes, to meet the needs of automotive electronics and other harsh environments.
3.High-performance signal transmission
Supports high-speed digital signals (USB3.0/HDMI), guarantees the integrity of high-frequency RF signals, and realizes lossless transmission of high-definition video and audio signals.
4.Space-optimized solution
Ultra-thin design (minimum 0.2mm thickness), high-density layout (minimum 0.3mm spacing), significantly improves the utilization of space within the device.
5.Convenient maintenance characteristics
Modular design supports quick replacement, standardized interface simplifies the maintenance process, and repeatable plug-and-play design (5000+ times).
With the development of electronic equipment in a lightweight, high-performance direction, the importance of FPC connectors will be further highlighted, and their functional value will continue to expand.
Advantages of FPC connectors
Small and lightweight, adaptable, easy to install, and highly reliable. Compared with traditional rigid connectors, FPC connectors can provide high-density connections in limited space, adapting to the needs of applications in a variety of complex environments. In addition, FPC connectors can also reduce signal interference and power consumption due to poor contact in traditional connectors to ensure stable signal transmission. The high-density connection characteristics of FPC connectors enable them to achieve multi-point connections in limited space, which is suitable for electronic devices that require a high degree of integration. The flexibility of FPC connectors makes them adaptable to different shapes and bends in the installation needs, especially suitable for applications requiring The lightweight features of FPC connectors help to reduce the overall weight of electronic equipment and enhance portability.
The manufacturing process of FPC connectors involves steps such as precision mold manufacturing, injection molding, press molding, and assembly. The manufacturing process of FPC connectors requires strict control of tolerances and dimensions to ensure high precision and consistency of the connectors. A high-quality manufacturing process can ensure the electrical performance and mechanical strength of FPC connectors and extend their service life.
FPC connector precision manufacturing process
1.Precision manufacturing process
1. Mold development stage
The use of micron-level precision mold processing technology and the use of a CAD / CAM integrated design system to achieve ± 0.01mm processing accuracy control.
2. Core component manufacturing
(1) Injection molding process
Selection of LCP/PA9T and other polymer materials, precision temperature-controlled injection molding system (± 1 ℃), and automatic optical inspection (AOI) to ensure dimensional tolerances.
(2) Stamping and plating process:
High-speed precision stamping (300 times/minute), selective plating technology (localized gold plating), plating thickness control (0.05-0.2μm).
3. Automated assembly
Robot precision assembly system, online laser welding process, vision positioning system (precision ±0.02mm).
2.Whole process quality testing system
1. Electrical performance test
Contact resistance test (four-wire method), insulation voltage test (DC 500V/60s), high-frequency impedance test (up to 40GHz).
2. Mechanical Performance Verification
Insertion and extraction force curve analysis (5- 20N range), mechanical life test (5000-10000 cycles), vibration test (10- 2000Hz sweep).
3. Environmental Reliability Verification
Extreme temperature cycling (-40℃~+125℃), Double 85 test (85℃/85%RH, 1000h), Salt spray corrosion test (more than 96h).
4. Special performance test
Bending fatigue test (200,000 times of dynamic bending), EMI shielding performance verification (up to 6GHz), air tightness test (IP68 rating).
Through this complete set of processes and quality control system, FPC connectors are able to meet the stringent requirements of 5G communication, intelligent automobile, high-end medical equipment, and other fields, providing reliable interconnection solutions for modern electronic devices.
What is the difference between FFC and FPC connectors
1. Definition and structure difference
FFC connector
FFC connectors, i.e. flexible flat cable connectors, are made of PET insulating material and extremely thin tinned flat copper wires, which are pressed together by high-tech automated equipment. Its structure is characterized by flat copper foil sandwiched between the upper and lower two layers of insulating foil, the finished product is simpler and thicker.
FPC Connectors
FPC connector (Flexible Printed Circuit board) is a flexible printed circuit board, the use of flexible insulating materials (such as polyimide or polyester film) as a substrate, through the printing process made of circuit boards. Its structure is complex, including multi-layer circuits and complex circuit layout, and is formed by processing FCCL (Flexible Copper Clad Laminate) through chemical etching.
2. Role and application differences
FFC connectors
With a high degree of flexibility and folding resistance, suitable for a variety of complex electronic equipment, such as computers, communication equipment, medical equipment, and industrial control equipment. Due to its standardized cable length and spacing, it is suitable for bulk purchase.
FPC Connectors
With multi-layer circuits and complex circuit layout capabilities, suitable for high-density, thin, and requiring multiple bending scenarios, such as cell phone folding screen, camera modules, smart wearable devices, etc. FPC connectors support high-frequency signals and anti-jamming, but the bending life is affected by the substrate.
3. Cost and process differences
FFC connector
The manufacturing process is relatively simple, the use of materials at a lower cost so the price is more economical, suitable for large-scale applications.
FPC connectors
Higher manufacturing costs, the need for a customized etching process, but the high degree of integration can reduce the complexity of assembly.
The emergence of FPC/FFC connectors provides greater flexibility and reliability in the design of electronic devices. They play a key role in different applications and have become an integral part of modern electronic engineering.
Application Scenarios of FPC Connectors
FPC connectors are widely used in all kinds of electronic devices, including but not limited to:
Mobile communication devices, such as cell phones, tablet PCs, smart watches, etc., are mainly used to connect touch screens, displays, cameras, and other components.
Automotive electronics, such as various meters and control panels inside the car, need to meet the requirements of high reliability and high performance.
Medical devices, such as electrocardiographs, blood pressure monitors, etc., are used for connecting controllers and sensors.
Industrial control: used to connect sensors, actuators, and other equipment to realize signal transmission and control.