Meeting Requirements for Smaller, Lighter but Robust FPC Connectors

A product of the miniaturization trend in electronics, FPC connectors fill the need for reliable interconnect solutions in increasingly complex and dense circuitry without adding size and weight. They are designed to survive in such high-temperature environments.

A key specification in this product category is the centerline or pitch, especially in applications where space-saving is a must. As tight as 0.2mm is available from Molex, while Amphenol offers 0.21mm and TE Connectivity 0.25mm.

In the Chinese mainland, manufacturers continue to push design capability to keep up with these market leaders. The current selections start at 0.3mm. Two suppliers interviewed by Global Sources Electronic Components, Shenzhen MUP Industrial Co. Ltd and Taiwan region-based Chyao Shiunn Electronic Industrial Ltd, are among those that have released FPC connectors with pitch this fine. The bulk of shipments for most Chinese enterprises, however, is in pitches of 0.5, 1 and 1.25mm.

Consumer electronics are the main market, accounting for 70 percent of total shipments of FPC connectors worldwide. In 2021, the value of this application is forecast to exceed $400 billion, according to Strategy Analytics, increasing from $358.5 billion in 2020.

This sector is projected to grow further in the years ahead, guaranteeing more opportunities for the FPC interconnects category. In the near term, wearable devices, smartphones and automotive electronics will be hot applications. Gartner estimates consumer spending on wearables will reach $81.5 billion by the end of 2021, rising by 18.1 percent from 2020. The research and advisory company attributes this to the pandemic-driven shift to remote work and heightened awareness of health monitoring. This trend is anticipated to continue through 2022.

Chinese companies interviewed said these upbeat projections and sales growth in 2021 are encouraging suppliers to plan expanded production. They estimate output will increase by at least 10 percent and possibly as much as 20 percent in 2022.

There are hundreds of manufacturers of FPC connectors in the Chinese mainland, more than 70 percent of which are small and midsize domestic enterprises. The major players include Luxshare-ICT, Shenzhen Deren and Zhejiang Yonggui. They are joined by key foreign companies such as Molex, Tyco, Amphenol, JST, Kyocera and HRS that also have factories in the country.

To compete with these industry giants, Chinese suppliers offer a shorter lead time, lower prices and greater flexibility for small orders. They serve domestic and overseas markets, allocating 30 to 80 percent of production to the latter. The main export destinations are Europe, North America and the Asia-Pacific region.

The manufacturing hubs for the category are in the cities of Shenzhen, Dongguan, Kunshan, Suzhou and Yueqing.

Up to 3.96mm pitches

Miniaturization aside, Chinese companies continue to turn out FPC connectors for large devices as well, to serve various specifications. They have selections with pitches of 0.3, 0.5, 0.8, 1, 1.25, 1.5, 2, 2.54, 2.75 and 3.96mm and height ranging from 0.9 to 2.5mm.

By configuration, there are ZIF, non-ZIF, front- and back-flip, single- and dual-row, vertical and horizontal types. These have two to 96 poles.

Common electrical properties are 100mohm maximum contact resistance, 50Mohm minimum insulation resistance and 150VAC withstand voltage, while operating temperature is usually -55 to 85 C.

Most manufacturers offer FPC connectors with safety approval based on CE and UL standards, and with an RoHS certification.

Customization drives production and is the reason Chinese suppliers are improving their capabilities in plastic injection molding and metal processing to meet any connector pitch and height requirement, in addition to ensuring overall product reliability.

Companies obtain copper, bronze, gold, nickel and thermoplastic from domestic providers, but are open to other material sourcing options.

Input costs rose slightly in recent months, leading to 5 to 10 percent higher product prices. Some suppliers, however, kept their quotes unchanged to win more orders.

It may be 2022 before costs and prices stabilize.

0.3mm-pitch FPC connector

This JS-1194D-XX Series from Chyao Shiunn Electronic Industrial Ltd is a 0.3mm-pitch FPC connector with 40mohm maximum contact and 50Mohm minimum insulation resistance, 250VAC/min withstand voltage and -55 to 85 C temperature range.

The negotiable minimum order is for delivery within seven days.

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0.5mm-pitch FPC connector

Hsuan Mao Technology Co. Ltd's 0.5mm-pitch FPC connector, the C3947-XXDGR100R, has phosphor bronze contacts, brass solder tabs and a UL94V-rated housing.

Order quantity is negotiable. Lead time is seven days.

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0.3mm-pitch FPC connector

Rated at 30VAC/DC, 0.2A, the MUP-F302-5441 FPC connector from Shenzhen MUP Industrial Co. Ltd has 100mohm maximum contact and 50Mohm initial minimum insulation resistance, 150VAC/min withstand voltage and -55 to 85 C operating temperature. This front-flip unit, with 0.3mm-pitch and 1mm height, has copper alloy contacts and a UL94V-0-rated thermoplastic housing.

The supplier requires a minimum order of 500 units and the lead time is 14 days.

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Four- to 80-pin FPC connector

Available in versions with four to 80 pins, the HW05202*-7373 FPC connector from Zhejiang Wenda Electronics Co. Ltd has 50VAC/DC and 0.5A rated voltage and current, 500V withstand voltage, ≤30mohm contact and ≥500Mohm insulation resistance, and -25 to 85 C operating temperature. This back-flip unit has 0.5mm pitch and 2mm height.

The minimum order is 2,000 units. Lead time is 15 days.

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