Wire to board connectors create removable electrical interfaces between wires or cables and printed circuit boards (PCBs). They allow signals and power to be transferred from an external system onto a PCB through a pluggable connection.
If you are looking for more details, kindly visit RHT.
Wire to board connectors come in a vast array of styles, pitches, pin counts, termination methods and materials to accommodate various applications and PCB design needs. Selecting suitable wire to board connectors requires understanding key properties like current rating, density, durability, termination style, and cost.
This article provides a comprehensive overview of wire to board connector types, design considerations, installation, reliability factors and usage in electronics. Read on for an in-depth look at implementing removable interconnects from wires to boards using wire to board connectors.
Wire to Board Connector Overview
Wire to board connectors provide an array of contact pins or blades soldered to a PCB that mate with a plug containing socket contacts wired to an external cable or harness. The main components include:
Plug Housing – Molded plastic or metal shell containing socket contacts that engage with the pins on the PCB. May include strain relief for cable anchoring.
Pin Header – Header mounted on PCB with pins that mate with plug sockets. Available in through-hole or surface mount termination.
Contacts – Spring metal pins and sockets make the electrical connection when mated. Various material and plating options.
Locking Features – Latches, screws, clips or other mechanical means to secure mating.
When connected, the wire to board connector creates a removable electrical bridge between the cable and PCB. Different arrangements accommodate varied needs.
Request PCB Manufacturing & Assembly Quote Now
Reasons to Use Wire to Board Connectors
Wire to board connectors offer several advantages versus permanent soldered wire connections:
- Removability – Connectors allow wires to be detached from a PCB for servicing, storage or transport.
- Interchangeability – Standard connectors enable swapping peripheral devices or cables quickly.
- Signal Breakout – Break wire signals out onto a PCB with proper connectors.
- Field Wiring – Assemble external harnesses separately and connect on-site with connectors.
- Durability – Robust connectors withstand repeated matings better than direct soldering.
- Orientation – Polarized connectors prevent improper insertion.
- Strain Relief – Integrated cable grips reduce stress on connections.
- EMI Containment – Metal shells shield signals for improved emissions and immunity.
Wire to board connectors facilitate quick assembly and reconfiguration of electronics systems.
Wire to Board Connector Types
Many types of wire to board connectors exist to address varied applications. Common classifications include:
Pin Header Connectors
- Male pins solder onto PCB
- Female socket plug for wires
- Found in single row, dual row and 2D grid arrays
Card Edge Connectors
- Contacts along edge of PCB plug into socket
- Allow inserting/removing board from housing
Board Stacking Connectors
- Enable plugging multiple PCBs together
- Standoffs provide alignment and spacing
FFC/FPC Connectors
- Interfaces flat flex cables to PCB
- Low profile discrete contacts
D-Sub Connectors
- Rectangular connector with pins on PCB
- Popular for higher density analog signals
Circular Connectors
- Cylindrical connectors for power and signals
- Robust metal shells, various sizes
Many other types exist like HDMI, USB, and proprietary connectors tailored for specific applications.
Key Connector Characteristics
Several properties differentiate wire to board connectors by suitability:
- Pitch – Spacing between contacts, typically 0.1” to 2mm
- Current Rating – Maximum current per contact, ranging from <1A to 10A+
- Voltage Rating – Maximum working voltage, often several hundred volts.
- Contact Resistance – Milliohm level resistance through mated contacts.
- Contact Material – Copper alloy with gold, tin, or other platings.
- Polarization – Use of non-symmetrical shapes and keying to set orientation.
- Materials – Metal or plastic housings for ruggedness or cost.
- Locking Style – Screws, latches, friction fits, etc. to secure mating.
- Termination Style – Through-hole pins or surface mount tails.
- Temperature Range – Usable range, industrial is -40°C to 105°C+.
- Hermetic Sealing – For waterproof, airtight connections.
- EMI Shielding – Metal shells block electromagnetic interference.
If you are looking for more details, kindly visit Wire to Board Connector Manufacturers.
These parameters guide connector selection for target requirements. Tradeoffs exist between size, cost, and performance.
Selecting Suitable Wire to Board Connectors
Follow these steps when determining appropriate wire to board connectors:
- Define Requirements – Needed characteristics like voltage, current, density, EMI, rigidity, etc.
- Choose Position – Placement of connector on board – edge, mounting hole, or mid-board.
- Estimate Size – Board space available and approximate connector dimensions.
- Select Type – Narrow options by pitch, contacts, style needed to meet specs.
- Research Specific Parts – Dig into details on polarizing features, latches, materials, etc.
- Analyze Tradeoffs – Compare alternatives on cost, availability, and performance.
- Prototype – Test connector for fit, mating/unmating, and electrical functionality.
- Qualify Reliability – Subject to environmental stress testing for robustness.
This structured selection process helps identify optimal connectors for the application that balance cost, size, and functionality.
Installing Wire to Board Connectors
Properly installing wire to board connectors helps ensure reliable performance:
PCB Footprints – Lay out board land patterns per manufacturer recommendations to match connector footprint and pinout.
Soldering Methods – For through-hole pins, wave or selective soldering. Reflow compatible for SMT.
Polarization – Position non-symmetrical connectors correctly as keyed on PCB layout.
Standoffs – Standoffs properly space stacked boards and align pins.
Strain Relief – Anchor cable to limit bending stress at junction of wires and contacts.
Conformal Coating – Seal areas around connectors as needed for environmental protection.
Mechanical Reinforcement – Use brace plates or supports if heavy cable or frequent mating is expected.
Assembly Process – Ensure heat and chemical resistance if connector installed before wash processes.
Proper planning, preparation, installation and post-processing validates connector performance and longevity.
Request PCB Manufacturing & Assembly Quote Now
Wire to Board Connector Reliability Factors
Several intrinsic factors affect wire to board connector lifespan:
- Contact Wear – Repeated mating and unmating can degrade contact surfaces over 10,000+ cycles. Gold plating helps minimize wear.
- Fretting Corrosion – Tiny movements during vibration or thermal cycling can cause contact oxidation. Tight tolerances and surface platings reduce effects.
- Contact Contamination – Environmental particulates and chemicals corrode contacts. Hermetic seals and connector encapsulation helps prevent ingress.
- Mechanical Fatigue – Housings and pins exposed to vibration or shock can crack or break conductor paths over time. Durable component materials and strain relief improves robustness.
- Solder Joint Cracking – Thermal cycling stresses combined with board flexing may crack solder joints and cause intermittent electrical failures. Proper design and installation helps mitigate risks.
Valid design margin, material selection, mechanical reinforcement, and inspection helps connectors meet target lifespan requirements under expected operating conditions.
Wire to Board Applications
Some example applications using wire to board connectors include:
- Computer Peripherals – Headers connect disk drives, expansion cards, fans and other accessories to motherboards and backplanes. Facilitates modular upgrades.
- Automotive – Robust sealed connectors link controller electronics to sensors, actuators, lighting, infotainment and other subsystems in harsh under-hood and interior environments.
- Consumer Electronics – Low cost board-to-board stacking connectors assemble multiple PCB modules into compact devices with flexibility for servicing.
- Industrial – Rugged connectors with EMI shielding safely breakout field wiring from interior control electronics operating in dirty factory environments.
- Telecom – High speed backplane connectors route differential signals between line cards and control processors with maintained signal integrity.
- Test and Measurement – Replaceable connectors allow various instruments like multi-meters and signal generators to safely interface test leads to live circuits.
Myriad applications in every industry depend on the flexibility of wire to board connectors for implementing detachable I/O interfaces.
Conclusion
Wire to board connectors enable removable electrical connectivity from cables to PCBs in countless electronic devices and systems. Their modular nature supports field servicing, flexible assembly, and product upgrades over time. However, designing connectors that withstand mechanical stresses and environmental conditions to achieve target lifetime requires material science and engineering expertise.
With increasing demands for data rates and connectivity, advancements continue in wire to board connectors and associated PCB layout practices. Engineers must balance high-speed signal integrity, power density, manufacturability, and cost when specifying appropriate connectors. Used judiciously, wire to board connectors empower maintainable, evolvable electronic system architectures.
Request PCB Manufacturing & Assembly Quote Now
Frequently Asked Questions
What are typical steps to design wire to board connectors into a system?
- Estimate needed density, voltage, current, and environmental ratings based on system requirements
- Research suitable connector families and components based on constraints
- Create initial connector and PCB land pattern footprints with supplier CAD models
- Simulate electrical performance like impedance matching if high speed signals
- Prototype connections to validate mechanical and electrical functionality
- Perform environmental stress testing - thermal cycling, vibration, etc.
- Iterate on design as needed to pass qualification requirements
How are wire to board connectors specified for high frequency signals?
Precision impedance matched connectors would be utilized. This may entail wire to board coaxial connectors combined with PCB controlled impedance routing, dielectric material selection, and simulations to match impedances across interfaces.
What are some key considerations for connector placement on a PCB?
- Accessibility for mating/unmating - clearances for tools, hands, etc.
- Clearance from housing walls and internal components
- Separation from heat sources that may impact temperature rating
- Mechanical stability – locating connectors in areas with minimal flexing or vibration
- Panel cutting considerations to expose external connectors like D-Subs
How can wire to board connectors be protected from dust and liquids?
- Specify connector housings or plugs with sufficient IP rating for the environment
- Use caps or covers to protect unmated connectors
- Apply conformal coating around connector region
- Heat shrink or potting material around cable junction
- Avoid exposure to contamination during handling and installation
What testing validates wire to board connector reliability?
0 Members and 1 Guest are viewing this topic.
The company is the world’s best Custom Memory Card Connector supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.
Infraviolet
Board to board wire connectors advice
«
on: March 11, , 07:29:14 pm »
What do people tend to use for board-to-board wiring? Especially in circumstances where the different boards can move relative to each othr (like parts at ends of robotic limbs, or like wired hand held controllers for otherwise static devices).
I learnt a long time ago never to trust soldered wires for this, single core would break internally after cycles of bending, and be annoyingly springy before that. Multi-core would break very quickly at the space between the solder and the insulation, absolutely ****ing nightmare.
I've used pre-made crimped cable assemblies and appropriate header types, but these are annoyingly expensive.
I've found Molex Picoblades particularly useful, but the cost for the cable assemblies is very nasty (it's a ****ing piece of wire and some crimped ends and plastic housings, how can it cost >£7), £0.5 per header I don't mind, but the cables are clearly overpriced. And they're a single source part too, if Molex discontinues the series I won't be able to get any more.
I haven't really found a particular 2.54mm pitch type for regular use.
Ideally I'm after, in a style for 2.54mm pitch and in another for a pitch in the 1.2/1.25/1.27/1.28 mm range, some sort of cable and header family which:
1. Is cheap, for pre-made cables as well as headers, and made by more than one manufacturer
2. Has through hole headers available (I use SMD a lot, but never for things like cables where forces can get exerted) (I looked in to FFC cables but they don't seem to ever have through hole headers for low conductorcount varieties)
3. Available for conductor counts of 4, 6 and 8, 6 being the most important
4. Has a single row of pins on the headers
5. Has compact connectors and headers, nothing huge, nothing like big molded wire ends on miniature D cables
6. Is available in side-entry format
7. Has some amount of "locking", whether that is an actual clasp or just the friction fit of things like Picoblades, not totally loose to pull away the way dupont leads on header pins are
8. Will not fit together reversed, connector shape enforces correct insertion orientation
9. Carrying capacity of >=50mA per conductor for any 1.2xmm options, >=500mA per conductor for any 2.54mm solutions
I looked at some JST, because I think there are quite a few clones made of those connector types, but for those I couldn't find evidence of through hole 1.2xmm headers existing, and got a bit lost trying to consider 2.54mm options.
What have people found works?
Or otherwise what workarounds have people been using to navigate between the impossibility of reliably using directly soldered wires (and inconvenience for disassembly), and the nasty prices of cable asemblies?
Thank you
rdl
Re: Board to board wire connectors advice
«
Reply #1 on: March 12, , 04:47:18 am »
I don't know of anything that will meet all those requirements. I use Molex SL a lot and they can cover many of them. The problem there is you'd need a proper crimping tool. If you haven't already, read through this thread. Maybe it'll give you some better ideas.
https://www.eevblog.com/forum/reviews/affordable-crimp-tools-for-small-connectors-(dupont-etc-)/
Jwillis
Re: Board to board wire connectors advice
«
Reply #2 on: March 12, , 04:54:50 am »
Depends how many wires there are. Ribbon cable like that use for Parallel ATA (PATA)in a desk top computer or Flexible Flat Cables (FFC) like inside a printer.
For cables that require constant bending I try to use fine stranded silicone cables. You can get silicone ribbon cable as well. But any fine stranded wire would work.
I try to avoid soldering to the board only but rather use a cable to board anchor as well. This can be a wire to board connector or looping the cable through an anchor holes on the board. In a pinch, hot glue has worked . That way your insulation is also anchored to the board and not just the solder joint.
Removable connectors should be something that will lock together like DIN connectors or similar idea that also anchor the insulation.
JST have many Types of connector, each used for different applications. SM (2.5mm Pitch), RCY (2.5mm Pitch), SHD (1mm Pitch), GH (1.25mm Pitch), ZH (1.5mm Pitch), PA (2mm Pitch), PH (2mm Pitch), XA (2.5mm Pitch), XH (2.5mm Pitch), EH (2.5mm Pitch), RE (2.54mm Pitch), VH (3.96mm Pitch) neither of which is compatible with each other.
There are literally thousands of connectors for specific applications, voltage and current requirements. But mainly you want the insulation on the wire to be secured to the connector to relieve strain on the wire.
Veketti
Re: Board to board wire connectors advice
«
Reply #3 on: March 12, , 07:25:06 am »
Well, I don't have extensive experience nor pro in this matter, but I've used Molex mini-spox and still use, but to be honest JST-HX from Aliexpress seems to do the job as well. Actually the connectors do hold tighter than Mini-Spox. Then I've switched to flexible silicon wires, which are breeze to route and handle. They just stay where you put them and not cause any bending forces. Only downside is the crimping. Need to be extra careful that the wire holds after crimping. Maybe it's due to the extra thin strands. Buying these silicon wires locally is not viable cost wise so again Aliexpress is your friend with a fraction of price.
rdl
Re: Board to board wire connectors advice
«
Reply #4 on: March 12, , 10:05:58 pm »
Another type that might be worth looking into is IDC connectors. The kind that use normal ribbon cable, like what was used on floppy drives and older HDDs. They're all double row though. I think you can get them as small as 4x4, If you can work around that, they do a pretty good job and require no special tool to crimp. They're basically a right-angle style connector so you have to plan ahead a bit.
tooki
Re: Board to board wire connectors advice
«
Reply #5 on: March 14, , 11:22:15 pm »
I really like 1.27mm pitch box headers. They exist in both SMD and THT, and the IDC females crimp on easily with a small vice or parallel-jaw pliers. They are, however, only available in dual-row.
MathWizard
Re: Board to board wire connectors advice
«
Reply #6 on: March 15, , 08:55:39 pm »
I bought a recommended crimper, but I haven't bought the plastic bits yet, or small gauge wire or metal bits.
I have some old PCB's with headers, and some random wire cables, from printers/etc. I never had a hotair gun years ago, so I barely salvaged any headers/wire combos.
Infraviolet
Re: Board to board wire connectors advice
«
Reply #7 on: March 16, , 09:50:44 pm »
tooki, could you give some links to examples of both the board connectors and the mating cable connectors? Are thesea standard type, or lots of different incompatible single-manufacturer options? Aren't the IDC connectors that one mounts on to ribbon cables often really bulky, like several cm in two of their dimensions, maybe I'm misinterpreting the type you are trying to describe. Pictures would be helpful.
Thanks
tooki
Re: Board to board wire connectors advice
«
Reply #8 on: March 17, , 08:05:46 am »
They’re exactly like normal box headers and IDC connectors, but in miniature: smaller headers, smaller connectors, thinner, narrower ribbon cable.
They’re not proprietary, I’ve had no trouble whatsoever mixing various brands from Digi-Key and no-name from aliexpress.
The official ESP32 debugger board, the ESP-PROG, is a great example because it has both its UART and JTAG ports in both 0.1”/2.54mm and 0.05”/1.27mm headers side by side, so you can see a direct size comparison. See attached pic.
EPAIII
Re: Board to board wire connectors advice
«
Reply #9 on: March 17, , 08:19:45 am »
The first thing about connections between boards is what kind of signal are they passing. A 5 Amp, DC power supply connection needs one thing and a 1 Ghz serial digital or RF signal needs another.
When I have had multi-board projects to knit together the first thing I try to use is 0.05" ribbon cable with ID (insulation displacement) connectors. I used dual row headers, not single row ones. They are just far more common and easy to source. And PCB traces can be routed between the pins of one row to bring all of them out one side. The ID connectors make the construction of the interconnect cables so easy and quick and you can use either inexpensive tools or just a bench vise.
And for connections outside of the box or chassis, there are ID style, D sub-miniature connectors. Again, quick and easy to apply.
ID connectors on ribbon cables have saved me days of work on some projects.
Once I have as many of the connections as possible going through the ribbon cables, then I look at the remaining ones to see what their requirements may be.
As for movement, you need to look into the subject of strain relief and cable management. Almost any type of cable can be damaged if it is not installed properly. The first rule is stranded wire, not solid. Some connectors have built in strain relief and devices to limit the radius of bends. And you can use improvised means, such as flexible tubing over the wires. The ID connectors for ribbon cable have strain relief additions that also help to control the flexing. I have never had such a cable, with the strain relief pieces installed, break due to flexing. But care should be taken in the installation and routing of the cables when a lot of bending is anticipated.
« Last Edit: March 17, , 08:28:15 am by EPAIII »
Paul A. - SE Texas
And if you look REAL close at an analog signal,
You will find that it has discrete steps.
The following users thanked this post: tooki
Infraviolet
Re: Board to board wire connectors advice
«
Reply #10 on: March 19, , 07:25:22 pm »
Thanks, the 1.27mm pitch IDCs look worth more investigation now I see what you mean by them.
The following users thanked this post: tooki
tooki
Re: Board to board wire connectors advice
«
Reply #11 on: March 19, , 09:17:29 pm »
Thanks, the 1.27mm pitch IDCs look worth more investigation now I see what you mean by them.
I think they’re delightful little buggers. I’ve used them in two projects so far and have been really happy with them.