Cheap, high density connector for prototyping?

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Discussion Overview

The discussion revolves around finding affordable, high-density connectors suitable for prototyping low current devices such as temperature probes and LCDs. Participants explore various connector options, their practicality, and associated costs, without reaching a consensus on the best solution.

Discussion Character

  • Exploratory
  • Technical explanation
  • Debate/contested

Main Points Raised

  • One participant shares a link to a connector from SparkFun and expresses a need for a high-density connector that is not rugged and is affordable.
  • Another suggests using RJ-45 connectors, noting that while they may not fit perfectly on prototype boards, they are a cost-effective option.
  • A participant acknowledges having RJ-45 crimp tools but expresses concern about the small wire size.
  • One participant raises concerns about the relationship between connector density and cost, explaining that higher density typically leads to increased manufacturing costs due to the need for better materials and precision.
  • Alternatives proposed include using printed circuit boards with flex cables or redesigning connections into a high-speed serial bus.
  • A suggestion is made regarding the use of male headers, which are available in various sizes and are inexpensive and easy to work with.
  • Links to RJ-45 breakout connectors are shared, with participants expressing enthusiasm about their affordability and utility.

Areas of Agreement / Disagreement

Participants do not reach a consensus on a single best connector solution. Multiple competing views and suggestions are presented, reflecting differing opinions on practicality, cost, and suitability for the intended applications.

Contextual Notes

Participants discuss the trade-offs between connector density, cost, and mechanical reliability, highlighting that higher density connectors may incur additional costs due to material and manufacturing requirements.

Who May Find This Useful

This discussion may be useful for hobbyists and engineers involved in prototyping electronic circuits who are seeking cost-effective connector 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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