As the complexity of electronic designs grows, so does the need for connecting multiple printed circuit boards (PCBs) in compact, efficient ways.
Whether you’re working on automotive systems, industrial controls, or consumer electronics, selecting the right connector for multi-board setups is crucial.
At Hitaltech, we understand that every application has specific demands, ranging from signal and power requirements, space limitations, production processes, and environmental conditions.
Here’s an overview of key factors and solutions for connecting PCBs, including insights into when rigid or flexible connectors are the right fit.
Understanding the Connector Types: Rigid vs. Flexible
When connecting multiple PCBs, designers often face the choice between rigid and flexible interconnect solutions. Both offer unique advantages based on the application, so understanding these benefits can lead to a more reliable and cost-effective design.
Rigid Connectors: For Stable, High-Density Connections
Rigid connectors provide stability and are ideal for setups where PCBs are aligned in fixed positions. These connectors typically offer multiple connection points, making them suitable for high-density applications where numerous signals or power pathways are necessary.
Key benefits include:
- Stable, high-contact connections: Ideal for low-voltage and low-current setups, rigid connectors offer reliable connections for stacked or closely aligned boards.
- Modular configurations: Rigid systems support configurations such as motherboards with daughterboards, making them valuable in applications where modularity is essential.
- Through-hole and SMD options: Our Conex-it rigid connectors can be configured for manual insertion or automated reflow soldering, allowing flexibility in production processes.
However, rigid connectors are generally suited for shorter bridging distances and more controlled, stable environments. They are an excellent choice when boards are positioned parallel or perpendicular with minimal need for movement.
Flexible Connectors: Adaptability for Complex Configurations
Flexible connectors, such as Flexible Flat Cables (FFC), offer a versatile solution, especially when PCBs are separated by larger distances or placed at varied angles. Benefits of flexible interconnects include:
- Freedom of design: Flexible systems enable PCB connections over significant distances and across complex geometries, even if the boards are not perfectly aligned.
- Vibration resistance: In applications prone to movement or vibration, such as automotive or industrial equipment, flexible connectors can dampen vibrations, protecting sensitive connections.
- Adaptability to various soldering methods: Available in both through-hole and surface-mount configurations, flexible connectors integrate well into automated assembly lines, allowing efficient mass production.
Choosing the Right Connection for Your Application
With applications ranging from small consumer electronics to large industrial systems, determining the ideal connection method requires a nuanced approach. Here’s a closer look at when each solution might shine.
When to Choose Rigid Connectors
- Stacked or Parallel Board Layouts: For stacked configurations or when PCBs need to be plugged and unplugged easily, rigid connectors offer structural stability and a secure connection.
- High-Density Requirements: Applications needing numerous connection points in a compact space benefit from rigid connectors, available in ultra-fine pitches with multiple rows.
- Modular Design: Rigid connectors are suitable for modular setups, allowing optional daughterboards to connect easily with the main board. This flexibility is essential in designs where expansion or component upgrades are considered.
When to Choose Flexible Connectors
- Extended or Complex Layouts: For products with a more dynamic design, such as those requiring angles beyond 90 degrees or spanning greater distances, flexible interconnects allow creative layouts without compromising connectivity.
- High-Vibration Environments: Flexible cables absorb and dissipate vibrations, making them ideal for automotive and industrial sectors. Hitaltech’s flexible connectors, including our SMD and FIX jumper systems, provide robustness against bending and vibration.
- Space-Constrained Designs: As flexible connectors fold and bend, they fit well in compact spaces, enabling designers to maximize available volume within devices.
Advanced Solutions from Hitaltech
Our wide range of board-to-board solutions offers both standard and custom options tailored to your needs. Whether you need a robust solution for demanding industrial applications or a lightweight, flexible connector for consumer electronics, we provide high-quality, innovative products designed to meet stringent standards. Here’s a closer look at some of our specialised interconnect solutions:
- SMD Jumpers: Our Surface Mount Device (SMD) jumpers offer compact and cost-effective solutions for sandwiched or angled PCB assemblies. Available in various pitches, these jumpers are ideal for applications requiring automated pick-and-place processes.
- Round-Flat-Round Technology: Designed for high vibration applications, this solution combines the flexibility of a flat wire with the secure connections of round ends, making it suitable for automotive and industrial equipment.
- Power Interconnects: Our FIX POWER jumpers handle currents up to 12 amperes, using round-flat-round technology to offer high vibration and bending resistance, ideal for power-intensive applications.
Considerations for Cost-Effectiveness and Reliability
Cost remains a consideration when choosing a connector, but it’s often the total cost of ownership, which includes assembly efficiency, reliability, and ease of use.
Rigid connectors may be simpler to assemble in modular designs, while flexible connectors may reduce costs in high-vibration applications by enhancing reliability and longevity.
The production process also matters; flexible connectors that can be soldered directly onto boards may streamline automated assembly lines, providing a more cost-effective solution in the long run.
Hitaltech’s 3D CAD Modelling Tool: Simplifying Component Selection and Design
To further streamline the design process, Hitaltech offers an interactive 3D CAD modelling tool on our website.
This tool provides engineers with easy access to detailed 3D models of our components, enabling them to visualise, test, and accurately assess each part within their designs. From pin headers and sockets to board-to-board flexible interconnect systems, this tool facilitates precise evaluation without the need for physical samples, saving valuable time in design iterations.
With features like component comparison, intuitive search by product name or part number, and integration with ERP and CAD systems, Hitaltech’s 3D CAD tool makes selecting and customising components simpler and faster. Engineers can also generate 2D drawings from the models for accurate documentation, and the tool’s export capabilities support over 150 CAD formats, ensuring compatibility across workflows.
Our 3D CAD modelling tool reflects Hitaltech’s commitment to enhancing design accuracy and efficiency, empowering engineers to make informed, quicker decisions at every stage.
Hitaltech: Your Partner in PCB Connectivity
At Hitaltech, we specialise in helping clients navigate the complexities of multi-board connections with flexible and rigid solutions tailored to your project.
With products ranging from high-density rigid connectors to flexible interconnect systems designed for vibration-prone environments, we offer a comprehensive libary of solutions under one roof. Our team is ready to guide you through your options and assist in finding the optimal connector for your application.
Explore Hitaltech’s Conex-it range for versatile rigid connectors, our flexible interconnect systems for unique and demanding applications, and our 3D CAD modelling tool for enhanced design support. Contact us today to discuss how we can support your product’s design and production needs.
