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Comprehensive technical analysis of on-board connectors
View:795    Date:2025-03-24

Here is the professional translation and structured organization of the board-to-board connector technical document:

Chapter 1 Fundamental Concepts & Working Principles
1.1 Definition & Functional Positioning
Board-to-board connectors are core components in electronic systems enabling signal/power interconnections between PCBs, with three essential functions:

  • Electrical interconnection: Establish reliable low-impedance conductive paths
  • Mechanical support: Provide physical alignment and stress buffering
  • Modular design: Enable rapid module assembly/maintenance

1.2 Typical Structural Composition

Component Material Properties Functional Requirements
Contact Terminals Beryllium copper/C5191 phosphor bronze Elastic modulus ≥110GPa, Conductivity >80%IACS
Insulation Base LCP/PBT/PPS CTI ≥600V, Heat resistance >260℃ (reflow)
Housing PA66/Glass-fiber reinforced PBT Impact strength >80kJ/m²
Alignment Mechanism SUS304 stainless steel Mating precision ±0.05mm

1.3 Working Principle Diagram (Illustration)

Chapter 2 Technical Characteristics Analysis
2.1 Core Performance Indicator Matrix

Performance Category Key Parameters Typical Range Test Standard
Electrical Contact resistance <20mΩ EIA-364-06
Insulation resistance >1GΩ IEC 60512-2
Mechanical Mating force 0.5-5N/pin MIL-STD-1344
Retention force >15N EIA-364-29
Environmental Temperature range -55~+125℃ IEC 60068-2
Salt spray resistance >48h ASTM B117

2.2 Electrical Characteristics Analysis
Contact resistance model:

R_c = \frac{ρ}{2a} + \frac{σ}{A}

Where:
ρ = Material resistivity
a = Contact point radius
σ = Surface film resistivity
A = Actual contact area

2.3 Mechanical Performance Highlights
Mating force control:

  • Bicurved contact design reduces 40% mating force vs single-point
  • Optimal plating: Au(0.25μm)+Ni(1.5μm)
  • 5° lead-in angle decreases peak force 30%

Chapter 3 Evolution & Technological Development
3.1 Product Classification
By pitch:

  • Standard: 2.54mm/2.0mm
  • Fine: 1.27mm/1.0mm
  • Ultra-fine: 0.5mm/0.4mm

By contact type:

  • Spring contact (75% market share)
  • Rigid press-fit
  • Welded (laser)

Emerging technologies:

  • Wireless connectors (60GHz mmWave)
  • Optical interconnects (≥28Gbps)
  • Anisotropic conductive film

Chapter 4 Material Science & Manufacturing
4.1 Key Material Technologies
Contact material evolution:

  • Traditional: Brass (28%IACS)
  • Improved: Phosphor bronze (50%IACS)
  • Advanced: Cu-Ni-Si alloy (800MPa, 45%IACS)

Insulation material comparison:

Material Dielectric Constant @1GHz Loss Factor Frequency Range
LCP 2.9 0.0025 >10GHz
PPS 3.1 0.003 3-6GHz
PBT 3.3 0.02 <1GHz

Chapter 5 Testing & Validation
5.1 Comprehensive Testing
Initial verification:

  • Solderability (245℃±5℃ dip)
  • Coplanarity (<0.1mm)

Environmental tests:

  • Thermal cycling (-55℃↔+125℃, 1000 cycles)
  • Damp heat (85℃/85%RH, 1000h)

Mechanical tests:

  • Mating cycles (20,000)
  • Vibration (20-2000Hz, 3-axis)

Chapter 6 Applications & Selection
6.1 Typical Applications

  • 5G Communications: Backplane connectors (112Gbps)
  • EV: High-voltage connectors (1000VDC)
  • Medical: IP68 waterproof
  • Industrial: Vibration-resistant (10-2000Hz)

6.2 Selection Matrix

Parameter Consumer Electronics Industrial Automotive
Pitch 0.4mm 0.8mm 1.5mm
Current 0.5A 3A 20A
Temperature -20~+85℃ -40~+105℃ -55~+125℃
Durability 50 cycles 500 cycles 5000 cycles





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