Connector Recommendations

[footballfanatic]

Hi all!

I have a project I'm working on and am at the stage of refining the physical enclosure and connectors. The core device enclosure is about 5cm x 10cm x 2cm LxWxD in size and receives data via an external FPC (10 x 1mm pitch traces) which must be attachable/detachable to the device enclosure. I was concerned about damaging the FPC terminal traces through repetitive insertion/removal from a ZIF connector so decided to make them attach to one another magnetically like a pogo touch connector. This would work by having a magnetic (instead of plastic) stiffener on the FPC terminal end. I have trawled through all connector styles on Mouser/Digikey and understand I may need to CMC machine some unique parts so throw any ideas you have at me!

Now I’m trying to work out the best method of connecting the PCB inside the enclosure to the external of the enclosure ready for mating with the FPC. I can think of two methods.

i) One would involve using a through-hole method which uses pins which embed into the enclosure for interaction with the external FPC, then on the inside of the enclosure the pins bend 90 degrees to insert into a through-hole on the PCB for soldering similar to this: http://www.pcssl.co.nz/productdetails.aspx?cmd=900-96

ii) The second method could involve another pins-embedded-into-enclosure style like above. Instead though, the ends of the pins inside the enclosure are short (2-3mm) and a second FPC connects these pins to an SMT ZIF connector on the PCB like this: http://www.heilind.com/products/molex/news/molex_smt_zif_connector.jpg

TL;DR: I need a method for connecting small pins embedded into an enclosure, which interact with the outside world, to the PCB inside the enclosure.
 
Kind Regards,

[jbb]

As a first approach, I'd look at ways to make the connection using something other than an FPC.  They can be a bit delicate...

I can think of 2 good ways to address this connection with an FPC.

• Solder a proper plug onto the end of the FPC. (Note: you can ask FPC manufacturers to add stiffening layers of polyamide or even FR4 fibreglass to make a flat spot for soldering.)
• Ask your FPC manufacturer about an FPC crimp connector like this.

[footballfanatic]

Thanks jbb,

The FPC housing for the external FPC is a great idea.

Any thoughts on the internal connection between the PCB and the mating pins embedded into the enclosure?

On that link you mentioned for the crimp connectors, it had a picture that serves as a good visualisation of what I was thinking for the pins embedded within the enclosure would look like (the pins on the bottom sticking out would be the internal side and go through-hole into the PCB for soldering, whilst the pins flat with the plastic are for external magnetic mating with the FPC housing).

Original TE picture: triomate2.png
My enclosure visualisation: triomate_roofless.png

[jbb]

Sorry for slow response.

I would suggest a female receptacle on the FPC (so there aren't pins to bend) and a male pin header on the PCB.

The typical solution would be a right-angle pin header that is a) through-hole for toughness, b) recessed back enough that the pins don't go outside the case and c) accessible through a simple hole in the case.  The hole might let some dust and dirt into the enclosure, though.

User-accessible plugs and sockets often take a bit of a beating, so it's worth thinking about toughness from the get-go.

How many are you doing?