FPC/FFC connectors

Strong demand from the portable electronics sector drives trend for smaller form factors despite high costs. Emerging applications help boost the industry.

China suppliers of FPC/FFC connectors are developing more-compact versions in response to the miniaturization trend in consumer electronics. This comes even as models with 0.85 and 0.9mm pitches continue to represent the mainstream.

Product development is geared toward units with smaller pitch and lower height but with greater pin density to maintain high data transfer rates. In this regard, many companies are setting their sights on 0.3 and 0.5mm pitch models, which only a few makers can offer at present due to cost considerations. Such designs require high-precision molding equipment.

The portable electronics segment is a major growth driver in the line. Strong demand from the mobile phone industry in particular has spurred orders for 0.3mm pitch connectors, which were developed and launched as early as 2004 by Japan and US suppliers. In fact, models with 0.3 and 0.5mm pitches now dominate global output. The 0.3mm versions commonly have 17, 21, 25, 31, 39, 45, 57 or 67 pins, while pins for 0.5mm units are from four to 60.

Japan has been taking the lead in developing models with even smaller pitches of 0.2 and 0.25mm. Their manufacture is said to be comparable to the production of the currently popular 0.4mm board-to-board connectors. This is because FPC/FFC connectors adopt a staggered pin design and have less insert/withdraw operations than board-to-board versions. Companies in China expect 0.2 and 0.25mm models to grab the spotlight in coming years, and are now conducting preliminary research activities.

Aside from keeping up with the latest trends, makers are boosting connector quality to better position their products and gain brand recognition internationally. One way is by upgrading facilities and testing equipment. Suppliers are also closely monitoring material sourcing and implementing strict QC procedures to achieve zero defect rate.

Further, companies in China are maximizing their price edge to attract orders. Quotes of FPC/FFC connectors from the country are 30 to 50 percent lower than foreign brands. Tyco, Molex, Amphenol, Omron, JST and JAE are among the leading industry players.

Still in line with efforts to enhance competitiveness, manufacturers are addressing environmental concerns by implementing IECQ QC 080000. Under the system, makers identify and control the level of hazardous substances in their products to meet RoHS and WEEE requirements.

Further, ISO 9001:2000 and 14001:2004 compliance is common and many export-oriented suppliers meet UL, CE and VDE standards.

Companies are also improving product reliability. One way is through the adoption of the zero insertion force flip-lock design commonly used for connectors that do not require frequent insertion/withdrawal operations.

In this construction, the rotating actuator permits easy connection and retention of the flexible PCB or the flat flexible cable. The tactile sensation confirms complete board or cable insertion and ensures reliable mechanical and electrical connection. Further, the actuator will not be dislodged when operating under harsh conditions.

China-made FPC/FFC connectors come in DIP and SMT types. The former fits into auto-insertion equipment, while SMT models are processed using surface-mount machines.

Aside from 0.3, 0.5, 0.85 and 0.9mm, FPC connectors are available in 1 and 1.25mm pitches, while FFC units come in 0.8, 1, 1.25, 1.27, 1.5, 2 and 2.54mm versions.

Suppliers are projecting stable prices throughout 2009 as there have been no drastic changes in material costs over recent months.

Phosphor bronze, plastic, copper foil, protecting film and stiffener are utilized in production. These manufacturing inputs are readily available from local providers, but can be imported on request.

With good stress intensity, surface smoothness and anti-combustion performance, nylon, polyester and PPS are the most-common types used for insulation. They comply with UL94V-0 flame retardant specifications.

Liquid crystal polymer is adopted in some upscale models. LCP is more rigid, possesses high dielectric strength and chemical resistance, and remains stable at high temperatures. It is suitable for ultrathin components, and is a good alternative to ceramic and thermosetting plastic used in sensors, motors, illuminating products and power supplies.

For the contacts, most China makers prefer phosphor bronze to basic brass or the expensive BeCu alloy. They are usually plated with gold or tin over 50µin nickel. Plating and thickness may be specified by customers.

	Model 1.24A-WS-NPF from Zhejiang Jinda has four to 40 poles and phosphor bronze contacts.

China’s FPC/FFC connectors industry has been growing 10 percent annually over the past several years, thanks primarily to the line’s versatility.

Products’ small volume, slim form factor, high precision and light weight encourage adoption in various A/V and office automation devices. Common uses include camcorders, flat-panel TVs and displays, CD and DVD players, keyboards, PCs, printers and POS systems.

Companies are anticipating further growth as demand from the mobile phone, PDA, GPS, and digital and video camera industries remains strong.

Suppliers also expect FPC/FFC connectors to be employed in automotive, aviation and other high-tech products such as satellite communication and military equipment.

Attracted by the segment’s rosy outlook and high profit margins, new players are likely to join the line in coming months. There are currently fewer than 200 FPC/FFC connector makers in mainland China, most of which are located in Shenzhen, Guangdong province.

North America, Europe, Australia and Southeast Asia are the key export markets, although shipments to Hong Kong and Taiwan increased significantly in 2008. Revenue from overseas trade is expected to rise by 10 percent this year.

Since FPC/FFC connectors are considered customized products, companies in the mainland emphasize mold esign and manufacture to cater more effectively to their OEM clients. This segment currently accounts for about 80 percent of business.

Key specifications such as number of positions, connector height, rated current, terminal pitch and material options for the contact mating area plating are provided by customers.

Factories have machines for pressing, drilling, plastic injection and connector assembly. Testing devices include optical projectors, 3D measurement systems and x-ray thickness gauges. To ensure quality, many companies import equipment from Japan, the US and Germany.

FPC/FFC types account for 10 to 60 percent of makers’ overall connector output. Utilization rates are at 60 to 90 percent.

Although demand remains robust, many suppliers have no immediate plans of expanding capacity this year due to economic uncertainties.

While China’s FPC/FFC connectors segment has been increasing steadily in past years, data from the China Electro Connector

Association shows that the reverse is true for the country’s overall industry. Total sales rose 15 percent in 2007 to exceed $8.5 billion but growth slowed to just 5 percent the following year, resulting in revenue valued at only over $8.9 billion. Suppliers believe that the situation will persist throughout 2009.

Even so, China remains the world’s largest provider of connectors, accounting for one-third of the global turnout. There are currently more than a thousand makers in the country, many of which offer a complete gamut of connectors. The most-common types are fiber-optic, PCB and RCA, and those used for computer, telecom and A/V products. Companies also provide modular jacks, telephone plugs and terminal blocks.

About 80 percent of suppliers cater largely to overseas markets, with Asia as the primary export destination. The majority ships more than 60 percent of output.

Nearly 600 enterprises run large and midsize production, and the rest manage small-scale and family-operated workshops. Big companies generally have annual sales of $20 million and above, while midsize makers generate $5 to $20 million. Small players make at most $5 million per year.

The majority of suppliers are local, with only 300 owned or invested by foreign entities.

Makers in Taiwan are leveraging their price edge and active product development to boost the island’s FPC/FFC connectors industry.

Designs are already offered at quotes relatively lower than those from top-tier industry players such as Molex, Tyco and JAE. Further, suppliers are continually enhancing performance to secure their current customer base and attract new buyers. R&D efforts are geared toward models with smaller pitch, lower height and more pins.

Designs come in a range of pitches, although 0.3 and 0.5mm models are currently the mainstream.

Easy-insertion connectors, said to be a low-cost solution for many board-to-cable applications, are also available. The products have a mechanical cover that can be pulled up or down. They come with a guide that helps adjust insert directions, ensuring easy and secured connections.

A major FPC/FFC connector supplier in Taiwan, Aces Electronic Co. Ltd offers easy-insertion models. It also provides board-to-board, card and customized connectors. FPC/FFC types are available in 0.3, 0.5, 0.8 and 1mm pitches. Actuators are preassembled with covers that secure the connection between the FPC/FFC and the connector terminals.

Aces also makes ultralow-profile SMT models for thinner and lighter devices. These have pull-type actuators and a height of 1.2mm. The products come in straight or right-angle version.

Besides standard applications, FPC/FFC connectors from the island are adopted in flat-panel displays and mobile phones. Makers agree that usage will extend to the automobile, medical and military sectors.

Taiwan has at least 100 FPC/FFC connectors suppliers. Since the product is widely adopted in laptops and the island accounts for about 90 percent of the world’s notebook PC shipments, output in the line is expected to remain stable.