Wire To Board Connectors: Key Models, Applications & Industry Trends

Wire To Board Connector: Analysis and Applications

Definition and Basic Principle of Wire To Board Connector

Wire To Board Connectors are electronic components used to reliably connect wires to printed circuit boards (PCBs). Their main function is to transmit signals, data, and power between different modules while ensuring connection stability and resistance to interference. The core principle relies on the elasticity and conductivity of metal contacts, forming reliable connections between wires and PCB pads. This ensures both mechanical robustness and stable electrical performance.

Structurally, a Wire To Board Connector typically consists of:

1.Housing: Usually made of plastic materials such as polyamide (PA) or polycarbonate (PC), providing fixation and insulation.

2.Contacts: Made from copper alloys or phosphor bronze, often plated with nickel or gold to enhance conductivity and corrosion resistance.

3.Locking Mechanism: Ensures the connector does not loosen during insertion and removal. Common types include plug-in, latch, or slide-in designs.

Design considerations include rated current, voltage, mating cycles, and operating temperature. Rated current ranges from a few hundred milliamps to tens of amps, and voltage can vary from low-voltage signals to high-voltage power applications.

Classification of Wire To Board Connectors

Wire To Board Connectors can be categorized in multiple ways, often included in the broader classification of types of Connectors. Key classification methods include:

1.By Connection Method

Through-Hole: Soldered through PCB holes, offering high mechanical strength and suitable for high-current or vibration-prone environments.

Surface Mount (SMT): Mounted on the PCB surface, enabling automated production and high-density designs.

2.By Pin Count and Pitch

Pin count ranges from 1 to hundreds. Common pitch sizes are 1.25mm, 2.0mm, and 2.54mm.

Smaller pitches allow higher integration but require higher precision in insertion and soldering.

3.By Application

Signal Connectors: Transmit low-current signals, e.g., for sensors or control boards.

Power Connectors: Carry higher currents, e.g., for DC-DC modules or LED drivers.

Classic Wire To Board Connector Models

Several Wire To Board Connector models have become industry standards:

1.Molex 22-01-2027

Pins: 2

Pitch: 2.54mm

Applications: Small signal transmission modules, commonly used in household appliances and computer peripherals.

Features: Gold-plated contacts, mating cycles over 25.

2.JST PH Series (e.g., PH 2.0)

Pins: 2–16

Pitch: 2.0mm

Applications: Consumer electronics, LED lighting, home appliances.

Features: Compact design suitable for high-density PCB layouts.

3.TE Connectivity / AMP 1.25mm Series

Pins: 1–10

Applications: Miniature electronic devices, communication modules.

Features: High-reliability contacts suitable for SMT automated production.

These classic models illustrate how different manufacturers offer various specifications based on application requirements and PCB density, which are key factors for engineers during selection.

Comparison with Other Types of Connectors

In electronic design, Wire To Board Connectors differ significantly from other types of Connectors, such as Board-to-Board Connectors or Wire-to-Wire Connectors:

Key Technical Parameters

Key parameters for selection and design include:

1.Rated Current

Depends on contact material and cross-section. Low-power signal connectors typically handle 1–3A; high-power connectors handle 5–20A.

2.Rated Voltage

Signal connectors usually under 50V, while power connectors can reach 300V or higher.

3.Contact Resistance

High-quality contacts are typically below 20 mΩ to ensure signal integrity.

4.Mating Cycles

Affects service life. Commonly 25–100 cycles, with high-end products reaching 500 cycles.

5.Operating Temperature

Standard materials: -40°C to +105°C; high-temperature materials: up to +125°C or +150°C.

Scientific evaluation of these parameters ensures stable performance in real-world applications.

Application Cases

1.Consumer Electronics

Mobile charging ports, LED modules, and smart home devices frequently use JST PH series and Molex miniature connectors.

2.Industrial Automation

PLC controllers and industrial sensors often employ TE Connectivity’s high-reliability SMT connectors for signal acquisition and power supply.

3.Automotive Electronics

CAN bus interfaces and onboard charging systems use Wire To Board Connectors to ensure reliable data transmission and power delivery.

Engineers typically select connectors based on PCB density, current requirements, and operating temperature in these scenarios.

Trends and Design Considerations

With electronics becoming more compact and faster, Wire To Board Connectors show the following trends:

1.Smaller Pitch, Higher Pin Count

E.g., 0.8mm or 1.0mm SMT connectors for compact devices.

2.High-Temperature Materials

Ensures stable operation in automotive and industrial environments.

3.Low Insertion Force Designs

Facilitates maintenance and increases connector lifespan.

4.Integrated EMI/RFI Protection

Prevents signal interference, ensuring reliable high-speed data transmission.

Wire To Board Connectors are essential for connecting wires to PCBs, directly impacting the reliability of electronic systems. Through careful selection, scientific testing, and innovative design, engineers can ensure stable and efficient operation across various applications. Classic models like Molex 22-01-2027, JST PH series, and TE Connectivity SMT types provide useful references. Compared with Board-to-Board and Wire-to-Wire Connectors, Wire To Board Connectors are uniquely suited for modular designs requiring high reliability and easy integration.