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I-PEX Connectors for Automotive Industry

I-PEX offers a variety of connectors that are ideal for the automotive industry. Below are some use case examples for typical automotive applications such as IGBT, PCU and BMS/CMU.

What is IGBT?

IGBT is the insulation grid bipolar crystal tube

IGBT is a transistor in the power semiconductor device, which is mainly used as a semiconductor switch in the switch in the inverter circuit of the driving motor.

Using our unique IGBT module without solder PRESS FIT terminal ISFIT® can eliminate traditional welding processes. In addition, ISFIT helps to minimize the risk of damaged circuit boards, and improves assembly to operate by using lower insertion than traditional needle -eye terminals.

What is PCU?

PCU is the power control unit

It is used to receive signals from the vehicle and command the IGBT module for power control.

What is BMS?

BMS is a battery management system

What is CMU?

CMU is the battery management unit

This is used to measure and monitor the battery state. Lithium -ion batteries need to be strictly controlled -the system/device will turn off power transmission in any abnormal state.

The ISH® series is the best choice for these various car modules. I-PEX’s unique spring wiring terminals provide high-long long-term contact reliability. These connectors also have excellent high temperature resistance and vibration resistance, and provide a variety of extremes.

Universal Design Concepts of Connectors

I-PEX connector product series encompasses a range of connectors that employ a universal design concept with multiple connection options. For PCB module products that require versatility across various electronic devices, utilizing connectors with a universal design concept means having the flexibility to choose from multiple connection methods. As the available connection options for PCB modules increase, the target device market expands accordingly. I-PEX recommends the use of universal design connectors that support a wider range of connection methods, especially when developing highly versatile modules

Examples of Universal PCB Modules for Target Electronic Device Markets

For instance, the I-PEX VS connector (0.5mm pitch) series offers multiple connection options such as ultra-fine coaxial cable, FPC, or FFC, all with the same PCB board layout

In addition, the I-PEX VS connector series (0.5mm pitch) and CABLINE®-CA connector series (0.4mm pitch) can be respectively mounted on EMC shielded connectors (ZenShield®) with a shared footprint

Therefore, if there are EMC issues during product development, it is possible to compare the universal connectors and the full EMC shielded connectors (ZenShield®) by creating an evaluation board with a common footprint. This enables customers to validate the requirement for full EMC shielded connectors from the early stages of development

Additionally, these connectors offer cable and FPC connection options:

0.5mm pitch, horizontal plug-in style, cable/FPC connectors

0.35mm pitch, vertical plug-in style, ultra-fine coaxial cable / FPC connectors

Universal FPC / FFC Connectors

The I-PEX EVAFLEX® series of automatic locking FPC / FFC connectors also feature universal design connectors that allow for the selection of either horizontal or vertical mating orientations for common FPC / FFC designs. As the mating direction can be changed without altering the FPC / FFC, this module can be applied to a wider range of device applications

The lock function of the connector

Connectors with locking functions can strengthen the mating retention force, which helps prevent disengagement of the connection. There are various types of locking methods for connectors.

With the development of high -performance and miniaturization of electronic devices, portable consumer devices such as personal computers, tablets and smartphones have become a well -known thing in our daily life. We take them wherever we go. However, the more frequent the number of portable equipment we carry, the greater the risk of accidents. Therefore, the cables and connectors used for mobile devices should have anti -impact and vibration resistance.

Connectors with locking function can enhance the sustainability of chimeric and prevent connection interruption. The connector has various types of locking methods.

1. Cabline® series lock function

A variety of extremely fine coaxial connectors in the Cabline® series have a lock function.

For example, Cabline®-VS II is a 0.5 mm spacing horizontal plug-in model. In the chimeric steps, first complete the chimeric of the public seat, and then rotate the lock cover on the public seat to the parent seat on the PCB.  

Maintenance data

For example, the comparison results of Cabline®-VS II 30P public seat show that the public seat with locks remains about 8 times without locks.

* I-PEX can also evaluate vibration, impact, drop test, etc. based on the conditions of the customer’s use

Cabline®-UM is a low-back vertical insertion connector with a 0.4 mm spacing. It has a unique lock cover structure and can achieve automatic locking.

The extremely fine coaxial connector of Cabline® with a lock function

Some Cabline® series also have FPC options

Cabline® FPC connector series with lock function

2. MHF® series lock function

MHF® small radio frequency coaxial coaxial connector series has an LK type and has a lock function. Its patented mechanical locking characteristics have greatly improved the maintenance of the public seat compared with similar small radio frequency coaxial connectors in the market. 

Maintenance data

For example, the public seat maintenance comparison of the MHF®i series connector shows that the MHF®i connector with a lock -locking holder (MHF®I LK) is about twice the MHF®i connector without mechanical lock functions.  

MHF® connector series with locking function

3. The lock function of theevaflex® series

EVAFLEX® FFC/FPC connector has an automatic locking function, which can realize a one -step chimeric FFC/FPC, which is stronger and durable than the traditional FFC/FPC connector. Its one -step operation also helps to increase productivity, and it is also designed for the automation of robots.

When the FPC / FFC with a gap is inserted, the Lock Pin with flexible rail shapes in the EVAFLEX® series connector will be locked. In addition, clicking real -time feedback will help prevent situations without completely chimi. The automatic lock structure is reliable to fix the FFC position with gap to create excellent maintenance to fight against tensile and vibration.

FPC maintenance data

For example, EVAFLEX® 5-HD 24P connectors, FPC’s maintenance comparison results show that the FPC with locks remains about 3 times without locks.

EVAFLEX® Connector Series with Auto-Locking Functions

4. The lock function of miniflex®

Miniflex®FPC / FFC connector is usually called Zifs or Lifs, and there is also an LK type with mechanical lock options.

The contact point of the lock generates high maintenance. These contact points are located on both sides of the connector and are designed to capture and maintain a specific incision area of the FPC. They need higher FPC maintenance, and to increase the ideal solution to the smaller PIN count to increase FPC.

FPC maintenance data

For example, the miniflex® 3-BFN series, 0.3 mm spacing, horizontal chimeric FPC/FFC connector, 19P FPC guarantee comparison results show that the maintenance of the LK type FPC lock is better than a connector without lock locks. Keep a height of about 1.7 times. 

MINIFLEX® connector with locks

Locking Functions of Connectors

I-PEX manufacturers connectors for a wide variety of equipment applications. We will discuss the “Locking functions of connectors” in this webinar.

Today, it is commonplace to carry high-performance electronic devices. However, the more often they are carried, the greater the risk of dropping them accidentally. Connectors with locking functions can strengthen mating retention and help prevent unintended unmating. 

Locking methods vary from connector to connector. 

For example, the EVAFLEX® FFC/FPC connectors have an auto-locking feature that can mate FFC/FPC with one action, making them more robust and durable than traditional FFC/FPC connectors. Its one-step operation also helps improve productivity and is also designed for robotic automation. 
There are lock pins with a flexible guide shape in the EVAFLEX® series connector that lock when inserting a notched FPC / FFC. Also, click feedback from the lock will help to prevent half-mating insertion. The auto-lock structure reliably holds the notched FFC, creating excellent retention force against pulling and vibration.

The CABLINE® series micro-coaxial connectors also have locking functions. 

For example, the horizontally mating connectors have a locking mechanism that is rotating the locking cover of the plug to the receptacle on the PCB after the plug is mated. It has a very simple structure and is designed for easy handling. Also, the locking cover can only be locked when mating is complete, so it will help to prevent incomplete mating of the connectors. 

The MHF® series micro RF connectors support a wide range of frequency bands that enable high-speed communication, and its low profile and small size design make it ideal for high-density and miniaturization of applications. The LK type, equipped with a locking function, has a structure that can be easily locked by sliding the lock. Its patented mechanical locking feature greatly improves the plug retention force compared to common micro RF connectors in the same category in the market. 

JunctionX specializes in the professional production, distribution, and sales of connectors/authentic substitute connectors, wire harnesses, cable products, and customized injection-molded parts, stamping parts. If you want to purchase or learn more about product solutions, please feel free to contact us through the following methods.

The connection method

There are many types of connectors, so when developing new equipment, you need to find and choose the most suitable connector. The following introduces the relevant characteristics of different insertions for small connectors used inside the electronic device.

When the cable, FFC or FPC connect the signal of the PCB board to another board, a connector is close to the surface of the board vertically. The connector near the end of the plate is called a horizontal plug -in withdrawal.

●The orientation of the connector church

In the case of the connector mother seat installed on the board and using the public seat for chimeric, the vertical insertion and unplugged connector’s entrance is facing up. This enables the circuit board during the assembly of the circuit board, and it is easy to check and position the insertion position of the positioning and positioning through the downward way.

However, in the case of using the panel -to -board FPC connector, it may be difficult for operators to align the public seat to the correct inserted position to assemble it, because the FPC covers the entire public seat and blocks the clearly on the board on the board. The sight of the mother seat.

In this case, it is important to provide a guidance (calibration) function for the connector. It allows users to use the fingertips to find the correct insertion position, while gently sliding the FPC public seat to the parent seat.

●The installation position on the board and the gap between other components

For vertical inserted connections, the public seat is inserted from the mother seat near the board and inserted, so even if the connector is in the middle of the board, it is not difficult to insert the connector. In addition, due to the relatively narrowing area of the activity gap around the connector, other components can be installed around the connector. Therefore, in design, the vertical plug -in connector provides more flexibility than the horizontal plug -in type.

On the other hand, for the horizontally inserted connection, the opening of the parent seat is facing the side, so the public seat needs to move parallel to the surface of the board to cock with the parent seat. Therefore, it needs to be installed around the direction of the opening direction of the parent seat of the board to ensure that it will not be hindered during the insertion process.

In addition, if you install a low -height horizontal plug -in connector in the middle of the board, the assembly process may become difficult, because during the cooperation process, the fingers of the FPC / FFC or the public seat will touch the end of the board. When designing a circuit board, considering the assembly process is very necessary. For example, a low -height horizontal plug -in and unplugged connector is usually placed on the edge of the circuit board.

●The height and effective chimer of the connector

Due to the affected direction of the insertion direction, the effective humility and length are affected by the length of the vertical plug -in and unplugged connectors, that is, the height size of the connector. In portable high -performance devices, such as smartphones and tablets, components need to be installed in a narrow and limited space. In this kind of device, the meta -device is required to be small and small in shape, but when the height of the vertical plug -in connector is reduced, it may be difficult to maintain a sufficient effective chimeric length.

For horizontal plug -in connectors, the effective chimeric length is affected by the length of the horizontal direction of the surface of the end of the plate, that is, the depth size of the connector. Therefore, compared to the vertical plug -in connector, while maintaining the effective chimeric length, it is easier to consider reducing the height of the connector that is level -to -inserting.

●The chimeric maintenance of the low height connector

The short -to -effective chimeric length means that the tolerance range between the chimeric position terminal is higher. Therefore, there may be higher opportunities to lose contact between the terminals. For example, the device is suddenly dropped, and then the chimeric position is moved. One of the methods to improve contact reliability is to strengthen the chimeric retention between the public and the mother seat by locking mechanisms such as friction or mechanical lock.

In addition, another method of replenishing vertical insertion connectors is to add appropriate buffer materials above the connector. Therefore, when the product shell is attached, the buffer material properly press the connector properly and fix the connector chimeric position.

This method can be considered when developing small portable devices, for example, the possibility of falling when carrying small devices. (*But, please be careful not to put too much pressure on the connector, because this may cause damage.)

●Insertion effect

Since vertical insertion connectors are used to insert into the public seat to realize the chimeric, a highly inserted vertical insertion conjunction connector may apply excessive pressure to the board end during the chimeric process. Therefore, when the assembly is not suitable for the pressure of pressure, such as the board of the tablet integrated module, you may need to take some measures, such as choosing a vertical insertion and unloading connector with a lower plug -in power. , Or choose a horizontal insertion connector.

●Summary of the characteristics of vertical insertion/horizontal plug -in unplugged connector

Vertical insertion and unplugged connector

Compared with the horizontal plug -in connector, the required interval area around the connector is narrower, and it is more flexible when the design board.

Even if the connector is installed in the middle of the board, it will not have much impact on the insertion process.

While maintaining an effective chimeric length, it may be difficult to reduce the height of the connector.

When the assembly high insertion force connector, it may apply too much pressure on the end of the board.

Horizontal plug -in withdrawal connector

Due to the relatively wider gaps near the opening of the connector, there may be unusable space on the board.

In the case of low and small connectors, the chimeric of the connector installed in the middle of the board may become difficult.

Compared with the vertical insertion connector, while maintaining an effective chimeric length, it is relatively easy to reduce the height of the connector

The pressure applied on the board during the assembly process may be smaller than the connecter vertically inserted.

The development history of micro-coaxial connectors

Micro-coaxial cables have an external conductor that provides electromagnetic shielding, making it less susceptible to external electromagnetic waves or noise. This provides the cable with high flexibility and excellent shielding performance. To harness these advantages, it is necessary to handle and terminate these small cables individually, enabling micro-coaxial cables to be used as jumpers for digital signal connections. In the past, micro-coaxial cables were only used in expensive equipment like medical devices due to the difficulty in producing stable-quality cables, and they were not widely used in general consumer electronics.

In the 1990s, laptops with color LCD screens became widely used, offering higher image quality and faster display transmission. As a result, micro-coaxial cables emerged as a highly flexible and high-speed transmission solution for connecting and disconnecting the display. I-PEX was at the forefront of developing a connector that efficiently and reliably connected micro-coaxial cables, along with the technology to attach these small-sized cables to the connector. In 1996, I-PEX introduced the world’s first micro-coaxial connector, “CABLINE® I,” designed for differential transmission of digital signals. It was adopted for the first time in consumer laptops as a jumper connection for digital signals using micro-coaxial connectors.

The development of ‘CABLINE®-VS

Around 2006, the LED backlight system started to be adopted for laptop displays. Around the same time, to improve the compatibility of display connections and help display manufacturers and panel consumers better control the supply and demand cycle of panels, the Video Electronics Standards Association (VESA) focused on standardizing the connectors for laptop panels.

I-PEX CABLINE® series micro-coaxial connectors had already been used in laptop display connections and gained widespread recognition in the display industry. To obtain VESA certification for connectors, I-PEX initiated a development project for a new micro-coaxial connector called CABLINE®-VS, which would enable high-speed signal transmission and high connection reliability in compact sizes and narrow pitches. (The name “VS” stands for “VESA Standard,” as the purpose of developing the connector was to obtain VESA standard certification.)

In August 2009, after a long development process and overcoming various challenges, CABLINE®-VS was certified as the panel standard connector for the VESA “16:9 Widescreen Notebook Panel with LED Backlight Standard.” Additionally, CABLINE®-VS received the “Outstanding Award” in the 14th ADY 2009 (Advanced Display of the Year) as a recognition of its contribution to the flat panel display industry. Today, CABLINE®-VS continues to be widely used as the standard connector for laptop displays and is highly regarded for its excellent performance and stability (I-PEX has shipped over one billion CABLINE®-VS connectors in the 10 years since obtaining VESA standard certification).

The present and future of micro-coaxial connectors:

With the development of high-speed internet and the increasing utilization of high-capacity storage devices, high-resolution images and videos can be easily shared on consumer products such as personal computers, tablets, and smartphones. The amount of information to be processed on these devices has dramatically increased, and the signal speeds of the devices have become faster. When electronic devices are exposed to external electromagnetic noise, unexpected electrical signals may interfere with the internal circuits, leading to failures or damage to high-performance electronic components and potential device malfunction.

As the next-generation panel connector of CABLINE®-VS, I-PEX is also developing EMC shielded connectors called ZenShield® to meet various applications and design conditions. ZenShield® connectors provide circuit board designers with greater flexibility by allowing the connector to be placed close to sensitive subsystems, such as transceiver antennas commonly found in high-performance wireless communication systems. These connectors enhance electromagnetic compatibility and shielding performance, minimizing the impact of external electromagnetic interference on electronic devices.

As data rates increase, servers rely more on cable assemblies. These cable assemblies need to minimize their size for easy assembly within server systems while maintaining unobstructed airflow for effective cooling. Flexibility is advantageous for both high-speed and low-speed internal cables, as well as for compact and low-height designs. Micro-coaxial cables, along with I-PEX CABLINE® series connectors, enable higher interconnect densities, reducing the system space required for wiring and cable assembly terminations. This allows for more efficient and compact server designs.

I-PEX is committed to continuously innovating and expanding its micro coaxial connector product line. We are committed to providing ultra compact connectors, excellent Signal integrity solutions and comprehensive technical support. The goal of I-PEX is to meet the constantly evolving needs of various industries and applications, providing reliable and high-performance connectivity solutions. I-PEX focuses on miniaturization, advanced technology, and customer support, aiming to stay at the forefront of the micro coaxial connector industry.

Very fine coaxial line plate connector

0.4 mm spacing, horizontal plug -in models with fine coaxial connector, with EMC shielding cover and mechanical lock

Product Size

Can provide PIN numbers and product size

Mechanical lock

Mechanical locks prevent the connector from falling off

High -performance EMC shielding design

I-PEX has developed a connector series that solves the problem of electromagnetic noise in the connector. It has a suitable ground structure and coverage layer, including the installation position of the signal terminal with metal shielding (Zenshield®) Essence This solution is widely adopted by many customers to prevent electromagnetic interference, especially on high-performance devices equipped with Wi-Fi, GPS, LTE and other wireless communication functions.

The 360 -degree EMC shielding design can not only prevent electromagnetic noise radiation from the contact point of the public and mother seats, but also prevent electromagnetic noise radiation from the lineboard installation part (SMT position) from the signal terminal. In addition, when the connector is cocks and correctly ground to the line board, the public seat and the mother seat shielding cover is correctly connected to multi -point ground. This ensures that the current generated in the metal shield of the connector has sufficient ground return path. This is to suppress the electromagnetic noise of the shielding layer.

►The entire connector is blocked by 360 degrees, including the public seat and the mother seat

►The shielding cover between the public seat and the mother seat-the shielding interface, effectively connect to multiple points。

►The interface of the connecter shield-line board is effectively grounded at multiple points, thereby improving the ground return path.

With these design characteristics, the connector itself provides a significant EMI relief. Zenshield® provides engineers with greater flexibility to design lineboards. It makes the connector closer to the sensitive subsystem, such as launch/receiving antenna, which is a common high -performance wireless communication system.

插入图片7

Automatic manufacturing and inspection process

Combine the type options

  1. PEX has a horizontal and vertical plug-in connecter series, which can choose the appropriate chimeric direction according to different applications and design conditions. For example, when a narrow -type connector is required on the board, a horizontally inserted and unplug connector can be used; when high -density installation is required in the middle of the board, vertical insertion conjunction can be used.

►0.4 mm spacing, extremely fine coaxial connector with EMC shielding and mechanical lock

Horizontal plug-in: Cabline®-CA II

Vertical insertion: Cabline®-UM

Introduction and Applications of ERNI SMC Series Connectors

SMC connectors (Small Multiple Connector) have a grid of 1.27 millimeters and are available with pin counts of 12 to 80. Reliable and compact connections can be made with them. Various shapes, such as straight or angled male and female terminal strips, enable different mating configurations. The combination of different height male and female terminal strips results in diverse board-to-board spacing. The SMC connector also supports wire-to-board solutions.

The SMC connectors offer ideal solutions everywhere small grid and high performance are required. The outstanding signal integrity and a relatively high current rating include an enormous variety of application possibilities.

Since SMC connectors work reliably under adverse conditions and are very robust, they are especially suitable for instrumentation and industrial applications. Areas of application of these safe, outstandingly processed elements are factory and process automation, industrial robots, switches or PLC controls and modular control systems for communication between controller and I/O modules use.

SMC connectors have a high contact density with low space requirements. They are suitable for  board-to-board or board-to-wire solutions. Via the connectors both high currents and high-frequency electrical signals can be transmitted.

Introduction and Applications of ERNI Power Taps Series Connectors

ERNI power taps in grids of 2.54 millimeters are developed especially for the power supply on the PCB and backplane. They are available in various designs with six or ten connection pins and as dip solder or pressfit variants. Depending on the cable connection and PCB, operating currents up to 40 amperes can be realized. For the variants with screw connection, the cable connection is possible with commercially available cable lugs. This provides high flexibility for the connections.

Our power taps can be used anywhere that PCBs must be supplied with power. Thanks to the high current carrying capacity of up to 40 ampere, even higher power can be transmitted via the taps. Dip solder and pressfit variants enable economical processes Typical applications can be found in the automotive area. Thus the ERNI power taps can be used for example in battery management systems for hybrid and electric vehicles.

Our power taps enable reliable transmission of electrical energy to the PCBs required for operation. They have a high current carrying capability and are flexible to process by pressfit or dip solder technology.

Introduction and Applications of ERNI MiniBridge Connectors

The ERNI MiniBridge connectors have a miniaturized shape in 1.27-mm grid and can be used everywhere that space-saving connections between PCBs and decentralized functional units must be implemented. The single row cable mating system is available with straight and angled male terminal strips. All mating variants can be used in combination with female terminal strips having 90° and 180° cable outlet. The Koshiri variants of the connectors offer especially high mating reliability.

The automotive area is one of the most important areas of use for the MiniBridge connectors. The connectors offer high vibration and impact resistance and meet the applicable specifications of  LV 214 for automobile connectors. Even high temperatures in the headlight area cannot harm the connectors.

Other areas of use are battery management systems and power electronics. Thanks to their compact shape, ruggedized and multiple mating variants, MiniBridge connectors are also widely used in the industrial environment. In medical technology they are in practical mating systems in ultrasonic devices, MRI devices, lab instruments and diverse diagnostic equipment..

MiniBridge connectors are an ideal solution everywhere that  there are space-saving, reliable and high rated connections. They are suitable for use in the automotive area or in industry and medical technology.