Cheap, high density connector for prototyping?

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SUMMARY

The discussion centers on finding affordable, high-density connectors for prototyping low-current devices like temperature probes and LCDs. Users recommend RJ-45 connectors as a cost-effective solution, despite their pin pitch not aligning perfectly with standard PCB dimensions. The conversation highlights the trade-offs between connector density and manufacturing costs, emphasizing that high-density connectors often come with increased prices due to material and design requirements. Alternatives such as printed circuit boards and high-speed serial buses are also suggested for users seeking different connection methods.

PREREQUISITES
  • Understanding of RJ-45 connector specifications and crimping tools
  • Familiarity with PCB design and environmental considerations
  • Knowledge of high-speed serial bus architectures
  • Experience with low-current electronic components and their connections
NEXT STEPS
  • Research the specifications and applications of RJ-45 connectors for prototyping
  • Explore PCB design tools for creating custom connectors
  • Investigate high-speed serial bus options and their chipsets
  • Look into various male header sizes and compatible female ribbon cables
USEFUL FOR

Electronics hobbyists, prototypers, and engineers seeking affordable and efficient connection solutions for low-current applications.

hxtasy
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https://www.sparkfun.com/products/8506

can anyone recommend a connector i can use, to say connect and discconect low current items such as temperature probes, LCDs, for all the prototyping circuits i make.

Circular connectors are high density but they are way too expensive, i don't need it to be rugged. Right now i find stuff laying around similar to that sparkfun link^ that already has pigtails and just solder and heat shrink unto it.

but now I am running out of those. computer/molex connectors just don't have the density I am looking for.

any suggestions, greatly appreciated.


thanks!
 
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If you get a crimper, you can use RJ-45 connectors. The females have a slight difficulty in that their pin pitch for the PCB end is not a nice clean 0.1" on center, but you can probably find versions that work for prototype boards...
 
Thats interesting, i definitely have rj-45 crimp tools. i don't like dealing with that small of a wire, but this is definitely a cheap solution.
 
anyone else have any ideas?
 
hxtasy said:
anyone else have any ideas?

Well with higher density comes less pin area to make the connection, so that will likely drive more expensive plating thickness - gold, etc, to provide the same impedance (AC and DC). Also, even if your application is particularly low current and low frequency (if so, what's the point?), there remains a similar mechanical stress per pin experienced during make/break that then must be distributed over less pin, again driving better materials and more precise manufacturing.

In other words, I would not expect the same price per pin in a high density connector that you would see in an 8 pin RJ-45. So then, once the pins are forced to be more expensive, given a more expensive product to start with the industry starts throwing in other features like air-tight seals with O rings, metal shells and strain relief. Voila, you have the expensive circular connectors you are seeing.

The above being the case, a couple alternatives have sprung up:
o Printed circuit board and flex cable (down to 0.5 mm pitch). But then you'll have to pay the overhead for the PCB, contain and mount the PCB if there are environmental issues, etc.
o Redesign your many connections into a high speed serial bus. Many are available with just your kind of problem in mind, and with chip sets to help out.
 
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Are male headers too big for your purposes? They make them all different sizes. They're cheap and easy to work with too. All you have to do is find a female ribbon cable to go with it.

Digikey has a large selection of headers.
 
hxtasy said:
https://www.sparkfun.com/products/716
RJ-45 break out connector
these are pretty sweet, price isn't too bad

then you can get some cat5 cables from monoprice for 50 cents

Nice find! I searched for a bit and didn't find anything, but that is perfect! :smile:
 

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