TABLE OF CONTENTS PRODUCT PORTFOLIO SUMIDA FLEXIBLE CONNECTIONS GMBH FLEXIBLE FLAT CABLES FLEXIBLE BOARD CONNECTIONS FLEXIBLE MODULES THT – THROUGH HOLE TECHNOLOGY PANTA FFC PANTA FIX JUMPER PANTA MODULES SMT – SURFACE MOUNT TECHNOLOGY PANTA SMD PANTA FLL REFLOW HOTBAR MCT – MATEABLE CONNECTION TECHNOLOGY PANTA FIX JUMPER PANTA ZIF JUMPER PANTA FIX CRIMP TABLE OF CONTENTS | FIX JUMPER TECHNOLOGY PANTA FIX JUMPERS are highly flexible flat conductor connectors to circuit boards (PCBs). Solid round conductors ensure a fast and safe assembly. The PANTA round-flat-round technology combines both. The copper conductors are rolled flat to a defined geometry in the insulating area. Ensuring the highest standards of vibration and bending resistance. The smooth notch-free transition from round to flat guarantees fracture-safe connection points. The following materials can be used for the insulation: Polyester, Nomex (Aramid), PEN (Polyethylenaphthalat) or Polyimide (Kapton). CHARACTERISTICS Through Hole Technology (THT) High vibration and bending resistance Reliable and fracture-safe connection Very easy handling Immediately ready for installation Economizes working time and assembly costs Minimum space required Wiring errors are avoided Choice of various termination styles Allows combination with male connectors High-quality insulation materials (-40°C to +125°C) Different pitches within one jumper available (MIX) Short insulation lengths also available as wire jumpers (without the flat rolled copper section) BENEFITS High vibration and bending resistance Smooth notch-free transition from flat to round Fracture-safe connection point Compensation of intrinsic vibrations Reduction of tension in the soldering area Avoidance of vibration resonances Please do not hesitate to ask for our processing instructions for PANTA FIX Jumper. 1 | Transition 2 | optimized distribution of stress PANTA FIX JUMPER | 1 ORDER CODE Pitch e.g. A=2,54 mm See pitch code FIX JUMPER Insulation material e.g. P = Polyester N = Nomex E = PEN K = Polyimide Termination Style e.g. A = identical ends AN = different (see chart, combinations on request) A 05 - N 051 - A Number of pins Insulation length from 15-5000 mm Special lengths on request Special designs on request, drawing required TERMINATION STYLES (D-L starting startingwith with11mm mmpitch pitc) B A PIN 1 C PIN 1 E D PIN 1 PIN 1 PIN 1 PIN 1 PIN 1 PIN 1 L K J PIN 1 G F PIN 1 H Z PIN 1 PIN 1 N A PIN 1 The respective termination styles can be chosen separately for each side and can also be combined with PANTA FLL-, PANTA FIX CRIMP and PANTA ZIF-terminations. PANTA FIX JUMPER | 2 TECHNICAL DATA FIX JUMPER A B D G C G Order Code D Pitch mm Max. number of pins A Length mm B Min. margin mm C Pin diameter mm American Wire Gauge G Flat conductor width Flat conductor thickness Voltage rating Dielectric strength E G 0,8 1,00 1,25 32 32 32 B L D F A Z 1,27 1,90 2,00 2,50 2,54 3,18 32 32 32 32 R P 3,5 C 3,81 5,08 32 25 23 20 16 0,3 0,3 0,3 0,5 0,5 15-5000 0,3 0,3 0,3 0,3 0,254 0,32 0,32 0,32 0,40 0,40 0,51 0,51 0,51 AWG 30 28 28 mm 0,5 0,7 0,75 μm 80 80 90 28 0,3 0,3 26 0,3 24 24 24 24 24 1,5 1,5 1,5 1,5 1,5 1,5 110 110 110 110 110 110 0,75 1,35 1,35 90 110 110 0,51 0,51 0,51 24 26 Cu acc. to DIN 40500; min. 1,5 μm tin-plated Conductor material Current rating at 20°C U 2-3 μm tin-plated A 0,5 1,0 1,5 1,5 2,0 2,0 3,5 3,5 3,5 3,5 3,5 3,5 VDC 100 200 200 200 200 200 300 300 300 300 300 300 VDC/min 200 700 700 700 1500 1500 1500 1500 1500 1500 1500 1500 Insulation Polyester Nomex With Pitch mm 2,54 American Wire Gauge AWG 24 Insulation resistance (grd-sig-grd) S >10 Operation temperature °C Soldering temperature °C/sec PEN Polyimide 10 -40 ... +105 -40 ... +125 -40 ... +125 -40 ... +125 250/4 260/5 260/5 260/5 PANTA FIX JUMPER | 3 ZIF JUMPER PRODUCT DESCRIPTION PANTA ZIF JUMPERS (FFC-Cable) are used for connecting printed circuit boards (PCBs) Compatible with ZIF (Zero Insertion Force) or LIF (Low Insertion Force) connectors Defined stripping of insulation and application of stiffener in the contact area provides secure connection to all conventional connection systems (e.g. Iriso, FCI, Molex, Tyco, JST etc.) Minimum dimensions through thin foils and small pitches Fast assembly by simple insertion High flexibility and bending resistance Special versions available, e.g. LIF/ZIF pins can be combined with round solder pins (PANTA FIX) or SMD solderable flat conductors (PANTA FLL) Optional custom design of jumper mating area allows the use of specific connectors with additional features. Specific punch at jumper ends provides a strain relief functionality and connector position assurance (e.g. Iriso I-Lock or similar) ORDER CODE Pitch e.g. E=1,00 mm See pitch code Insulation material e.g. P = Polyester E = PEN K = Polyimide Termination Style e.g. N = identical ends NW = different ZIF - E 10 - P 100 - N Number of pins Insulation length from 20-5000 mm Special lengths on request Special designs on request, drawing required PANTA ZIF JUMPER | 4 ZIF JUMPER FIELD OF APPLICATION CD-Player Printer Laptop LC-Displays Car-Radio Satellite Receiver Telephone ... CHARACTERISTICS Available pitches 0,5; 0,8; 1,0; 1,25 and 2,54 mm Temperature range -40°C … 105°C Copper wire can be chosen for a customer-specific coating with nickel and gold (conductor material Ni: e.g. min. 0.3 μm, conductor material AuCo: 0.1 μm)) Customer-specific application of isolation material Custom manufacturing of surgical exploration and reinforcements BENEFITS OF THE GOLD PLATING Low contact resistance Increased number of mating cycles Low current capability Prevention of whisker effect for small centerlines Connection with Au-plated connectors PANTA ZIF JUMPER | 5 TECHNICAL DATA ZIF JUMPER H H K K E D W G B E A N1 Order code D Pitch Max. number of pins N2 I E G A 0,5 1,00 1,25 2,54 70 30 26 24 1,25 2,54 A Insulation length 20-5000 E Margin 0,5 N Length of stripped insulation Nominal size (standard) 3-5 (4) 3-5 (5) K Length of reinforcement Nominal (standard) 6-10 (8) 6-10 (10) Conductor material G Wire material* 1,0 Tin-plated Cu - optional Ni/AuCo 0,30 x 0,10/0,05 0,70 x 0,10/0,05* Insulation 0,80 x 0,10 1,50 x 0,10 Polyester, PEN, Polyimide Reinforcing insulation Polyester B Total width (number of pins + 1) x pitch W Pitch width (number of pins - 1) x pitch H Total thickness of contact area 0,3 Insulation resistance (grd-sig-grd) >1010 Current rating at 20°C 0,5 1,0 1,5 3,0 Voltage rating 30 200 200 300 Operating temperature -40 ... +105 * customer specials on request PANTA ZIF JUMPER | 6 SMD PRODUCT DESCRIPTION The PANTA SMD jumper has been designed to connect sandwiched PCBs or PCBs positioned at different angles. It offers the user a great variety of possible configurations designing electronic devices. Applicable for reflow soldering process Competitive connection technique as an alternative to rigid-flex or milled pcb-solutions High temperature capability Placement by SMD assembly machines (automated Pick & Place) Post bending of printed boards possible after panel separation up to 180° CHARACTERISTICS Pitch: 0.93 mm Bridge length: 11.2 mm Total length: 15.2 mm Number of pins: 4-25 of 0,93mm pitch Packaging unit: 1500 pcs. on returnable reel Special pitches and other pin counts on request Customized SMD solutions available. 1 | Jumper placement for reflow process 2 | Possible post bending options after reflow up to 180° PANTA SMD | 7 ORDER CODE SMD Number of pins Pitch e.g. 0,93 mm Insulation length e.g. 8,3 mm SMD - 22 - 093 - K - 083 Special designs on request, drawing required Insulation material K = Polyimide N = Nomex TECHNICAL DATA 0,93 4 - 25 pol Insulation material Polyimide insulation 25 μm + adhesive S Insulation restistance A Max. number of pins 4 0,1 mm 2 0,1 Pitch 8 10 Complanarity mm 0,15 Min. bending radius mm 2,0 Max. bending cycle 20 x 135° Conductor material Cu 150 μm Sn 1,75 0,1 A IPC / JEDEC J-STD 020 D Resistance against soldering heat: -40°C to +125°C 33,0 Feeding direction 380 (350) °C 0,3 DIN EN 61760 Recommended reflow profile Operation temperature B 0,1 C 0,3 2* (DIN EN 60512-5-2) 2,1 0,2 Current rating at 20°C 14,2 0,1 (13,0 dia) PANTA SMD | 8 FLL PRODUCT DESCRIPTION Immediately ready for installation High vibration and bending resistance Suitable for SMT (e.g. thermode soldering / hot bar soldering) High-quality insulation materials (-40°C to +125°C) Minimum dimensions through thin foils and small pitches Standard contact zone 2.5 mm Short bridging lengths available CHARACTERISTICS Compatible with PANTA FIX with round solder pins Compatible with PANTA ZIF connections Special versions of insulation foil (punching of holes or trenches) Insulation material (e.g. NOMEX) suitable for thermode soldering/hot bar soldering ORDER CODE Pitch e.g. A=2,54 mm See pitch code Insulation material e.g. P = Polyester N = Nomex E = PEN K = Polyimide Special Drawing required FLL - A 05 - N 051 - 001 Number of pins Insulation length from 15-999 mm Special lengths on request PANTA FLL | 9 TECHNICAL DATA FLL D B G A Order code D Pitch mm Max. number of pins I U E G B D F A 0,5 0,8 1,00 1,25 1,27 2,00 2,50 2,54 6-50 4-30 4-30 2-30 2-30 2-16 2-16 2-16 A Length mm 12 - 999; special lengths up to 5000 B Total width mm (number of pins +1) x pitch G Flat conductor width mm 0,3 0,5 0,7 0,8 0,8 1,35 1,5 1,5 μm 100 100 100 100 100 100 127 127 Flat conductor thickness Cu acc. to DIN 40500; min. 1.0 μm tin-plated Conductor material Current rating at 20°C Voltage rating Dielectric strength A 0,5 1,0 1,0 1,5 1,5 2,0 3,0 3,0 VDC 30 100 200 200 200 200 300 300 VDC/min 100 300 700 1100 1100 1500 1500 1500 Insulation Polyester Nomex With pitch mm 0,5 - 2,54 American Wire Gauge AWG 24 Insultion resistance (grd-sig-grd) S Operating temperature °C Soldering temperature °C/sec PEN Polyimide >1010 -40 ... +105 -40 ... +125 -40 ... +125 -40 ... +125 250/4 260/5 260/5 260/5 PANTA FLL | 10 FIX CRIMP PRODUCT DESCRIPTION Solution to connect flat cable to round cable applications or header devices Assembly of foil crimp contacts from different manufacturers (e.g. Tyco, Nicomatic) with PANTA FIX JUMPER or PANTA FLEX cables Available pitches: 1.27 and 2.54 mm Secure connection (e.g. housings with locking mechanism and coding) Mate / unmateable space-saving connection Socket, pin and solder pin contact versions are available Available with tin- or gold-plated surfaces. CHARATERISTICS PANTA Crimp with TYCO contacts • TYCO pin contacts - 88117-x (gold-plated or tin-plated) on request - 88976-x (gold-plated or tin-plated) on request • TYCO socket contacts - 2-487406-4 (tin-plated) PREFERRED TYPE - 487406-X (gold-plated or tin-plated) on request • TYCO solder pin - 88997-2 (tin-plated) on request Diverse HOUSINGS are available on request. PANTA Crimp with Nicomatic contacts • Nicomatic socket contacts series 14106 TYCO Female Terminal 2-487406-4 - 14106-12 (tin-plated) PREFERRED TYPE - 14106-3210 (partially gold-plated) on request • Nicomatic Rectangular terminal series 12410 • - 12410-12 (tin-plated) PREFERRED TYPE - 12410-32 (partially gold-plated) on request Diverse HOUSINGS are available on request. We will be pleased to advise you. CRIMPFLEX® system patented by NICOMATIC PANTA FIX CRIMP | 11 ORDER CODE FIX CRIMP Pitch e.g. A=2,54 mm See pitch code Insulation material e.g. P = Polyester N = Nomex E = PEN K = Polyimide Special Drawing required CRP - A 05 - P 051 - 001 Number of pins Insulation length from 30-999 mm Special lengths on request TECHNICAL DATA Order code Pitch mm Compatible crimp contacts Preferred type Max. number of pins B A 1,27 2,54 Tyco Tyco Tyco MQS Nicomatic 1-487547-1 (gold-plated) 2-487406-4 (tin-plated) 929387-1 (tin-plated) 14106-12 (tin-plated) 32 20 32 32 Length mm 30 - 999 in steps of 1; special length up to 5000 Min. margin mm 0,8 Pin diameter mm 0,32 0,40 0,40 0,51 American Wire Gauge AWG 28 26 26 24 Flat conductor width mm 0,75 1,27 1,27 1,5 Flat conductor thickness μm 100 110 110 120 Conductor material μm Cu acc. to DIN 40500; tin-plated, 2 μm Current rating at 20°C Voltage rating Dielectric strength Cu acc. to DIN 40500; tin-plated 3 μm A 0,5 VDC 80 300 VDC/min 200 1500 2,0 2,0 3,0 PANTA FIX CRIMP | 12 FIX POWER PRODUCT DESCRIPTION High vibration and bending resistance Reliable and fracture-safe connection Ready for installation Economizes working time and assembly costs High productivity by simultaneous soldering of all connection points in the solder bath Up to 12 amperes (soldered power jumper) CHARACTERISTICS PANTA FIX POWER assembled with PANCON connectors MASCON series, Type CEH • Pitch 3.96 mm, high power • Number of pins: 2-8 • IDC termination (insulation displacement contact) • Wire gauge AWG 19 • Solid wires • Built-in polarization • Coding with coding pin • Current rating 6.0 A • Operating voltage acc. to VDE 0110-1/04.97 • Operating temperature -55°C to 105°C MASCON series, Type CEP (terminating connector) • Pitch 2.54mm • Number of pins: 2-15 • IDC termination (insulation displacement contact) • Wire gauge AWG 21 • Solid wires • Coding with coding pin • Current rating 4.0 A • Operating voltage acc. to VDE 0110-1/04.97 • Operating temperature -55°C to 105°C PANTA FIX POWER | 13 ORDER CODE Pitch e.g. A=2,54 mm See pitch code FIX POWER Insulation material e.g. P = Polyester N = Nomex E = PEN K = Polyimide Termination style e.g. A = identical ends AB = different (see chart) POW- A 05 - N 051 - A - 001 Number of pins Insulation length from 15-999 mm Special lengths on request Special designs on request, drawing required TERMINATION STYLES B A PIN 1 C PIN 1 PIN 1 PANTA FIX POWER | 14 TECHNICAL DATA B FIX POWER D G C A E1 E2 PANTA FIX POWER JUMPER Order code D Pitch mm Max. number of pins F A P N M C K J 2,5 2,54 3,5 3,96 5,0 5,08 7,0 7,5 15 15 8 8 8 8 8 8 A Length mm 25-999 in 0,1 steps; special lengths up to 5000 B Max. margin mm selectable up to 10 B Min. margin mm 1,0 1,0 1,0 1,0 1,0 1,0 1,0 1,0 C Pin diameter mm 0,72 0,72 0,91 0,91 0,91 0,91 0,91 0,91 AWG 21 21 19 19 19 19 19 19 mm 2,0 2,0 3,2 3,2 3,2 3,2 3,2 3,2 12 12 12 American Wire Gauge G Flat conductor width Flat conductor thickness μm 200 2-3 μm tin-plated Conductor material Current rating at 20°C Voltage rating Dielectric strength A 8 8 12 12 12 VDC 300 VDC/min 1500 PANTA FIX POWER | 15 TECHNICAL DATA FIX POWER PANTA FIX POWER SYSTEM with insulation displacement connector (IDC) The POWER Jumper D Pitch The HIGH POWER Connector mm Max. number of pins 2,54 3,96 Pitch mm 2-15 2-8 Max. number of pins 2-8 IDC A Length mm 25 - 999 Type of connection E Pin length mm 2,5 - 10 Wire gauge A,B or C Conductor type Termination styles B Min. margin mm 1,0 1,0 C Pin diameter mm 0,72 0,912 AWG 21 19 American Wire Gauge G Flat conductor width Flat conductor thickness mm 2,0/3,2 μm 200 Voltage rating Dielectric strength 19 solid Polarization integrated Coding by pins Current rating A Operation voltage 6 VDE 0110 b / 2,79 Table 4 Operation temperature °C -55 to 105 tin-plated 2-3 μm Conductor material Current rating at 20°C AWG 3,96 HI-POWER A 6 4 VDC 300 VDC/min 1500 The POWER Jumper - Insulation materials Insulation Polyester Nomex With pitch mm 3,96 American Wire Gauge AWG 19 Insulation resistance (grd-sig-grd) S Operation temperature °C Soldering temperature °C/sec PEN Polyimide >1010 -40 ... +105 -40 ... +125 -40 ... +125 -40 ... +125 250/4 260/5 260/5 260/5 PANTA FIX POWER | 16 FFC PRODUCT DESCRIPTION PANTA FFCs are flat copper conductors of various dimensions laminated with high-quality insulation foils. They combine minimum thickness with the precisely - defined, constant electrical values. BENEFITS Flexibility through flat copper conductors Highly vibration resistant Reliable and fracture-safe connection Minimum space required Weight reduction Suitable for signal and power distribution High thermal resistance High chemical resistance (meets automotive requirements) Wiring errors are avoided Hydrolyse resistance Highest flexibility Suitable for safety applications (e.g. air bags) Savings of cost and time during the process by simple and fast assembly CHARACTERISTICS We offer customized FFCs for automotive, industry and customer applications. Based on the customer requirements we develop specific solutions for all areas of applications. High-quality insulation foils in various thicknesses Flat copper conductor in thicknesses of 35 m and above Customer selection of copper width Use of ZZZIP® copper strip technology from Wieland Assurance of very tight tolerances by advanced manufacturing technologies Marking of the FFCs according to your specifications Highly precise window technologies Selective stripping of copper conductors by laser processing Punching technology for exposure of terminations Matrix connections available Assembly services (resistance welding, crimping, soldering, overmolding, potting) On request, we can produce the whole assembly for you. PANTA FFC | 17 ORDER CODE Pitch e.g. A=2,54 mm See pitch code FFC Insulation material e.g. P = Polyester N = Nomex E = PEN K = Polyimide Special Drawing required FFC - A 05 - P 1500 - 001 Number of pins TECHNICAL DATA* Insulation length selectable above 15 mm D A B B G Order Code D Pitch E mm G B D F A S Z R P N M C K J 1,00 1,25 1,27 2,00 2,50 2,54 2,70 3,18 3,50 3,81 3,96 5,00 5,08 7,00 7,50 Max. number of pins on request A Length mm selectable above 15 mm B Max. margin mm selectable up to 10 B Min. margin mm 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 G American Wire Gauge AWG 30 30 28 26 24 24 24 24 24 24 24 24 24 22 22 G Special wire gauges AWG - - 30 24 26 26 26 22 22 22 22 22 22 - - Conductor material Current rating at 20°C Voltage rating Dielectric strength Cu acc. to DIN 40500; min 1,5 μm tin-plated A 1,0 1,5 1,5 2,0 3,0 3,0 3,0 3,0 3,0 3,0 3,0 3,0 3,5 3,5 3,5 VDC 200 200 200 200 300 300 300 300 300 300 300 300 300 300 300 VDC/min 700 700 700 1000 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 Insulation Polyester Nomex With pitch mm 2,54 American Wire Gauge AWG 24 Insulation resistance (grd-sig-grd) S Operating temperature °C Soldering temperature °C/sec PEN Polyimide >1010 -40 ... +105 -40 ... +125 -40 ... +125 -40 ... +125 250/4 260/5 260/5 260/5 * customer specials on request PANTA FFC | 18 FLEXIBLE MODULES PRODUCT DESCRIPTION PANTA FLEXIBLE MODULES are customized applications. PANTA FLEXIBLE FLAT CABLES or PANTA FLEXIBLE BOARD CONNECTIONS are assembled with electronic components into a PANTA FLEXIBLE MODULE in our manufacturing process. BENEFITS Customized design Meets customer requirements Know-how of flexible connection technologies Combinations of technologies (e.g. lamination and molding process) PANTA FLEXIBLE MODULES | 19 PANTA - TECHNICAL EQUIPMENT FLEXIBLE MODULES LAMINATION Laminating is the process used to embed the copper conductor in insulating foil by using pressure and heat. The foils are coated with adhesive on one side. The copper conductors are parallel to each other. Different pitches can be combined. CUTTERS The laminated rolls are slit to the final cable width. The lengths of the cables are produced by the cross cutting afterwards. STRIPPING The cable terminations are made in a stripping process. The insulation is stripped off the copper wires using a special cutter. The conductor ends can then be processed further to the required termination style with specific bending tools. (For further information see PANTA FIX JUMPER on page 2) CRIMP-TECHNOLOGY Crimp connections to flat conductors of 1.27 mm and 2.54 mm pitch are possible with the crimping technology from Tyco and Nicomatic. (For further information see PANTA FIX Crimp on page 11) OVERMOLDING Fully hydraulic injection molding machines can be used to overmold the cable ends of FFCs or to assemble FLEXIBLE MODULES. The maximum injection volume is 15 cm³ with a projected area of max. 75 cm². PANTA FLEXIBLE MODULES | 20 PANTA - TECHNICAL EQUIPMENT FLEXIBLE MODULES POTTING WITH MACROMELT® Macromelt® allows clean processability and does not contain any solvents or other harmful substances. Macromelt® is particularly suitable for applications that require good adhesion to conductor or housing materials at low processing pressure. Macromelt® is injected with low pressure into the cavities. It spreads gently around even the tiniest components, seals and protects the components. STIFFENERS Special equipment places adhesive tapes and reinforcements onto our FFCs and ZIF jumpers. LASER PROCESSING A highly precise, powerful 300 W CO² laser implements fast and very flexible stripping modes. SOLDERING Selective soldering systems ensure optimum soldering while minimizing the heat stress for components. A reflow soldering system and placement systems are available for the assembly of SMD components. PANTA FLEXIBLE MODULES | 21 PANTA - TECHNICAL EQUIPMENT FLEXIBLE MODULES RESISTANCE WELDING The contact between the components and PANTA cables by means of resistance welding ensures a safe interface of very high quality. Welded flexible modules are later potted or overmolded in order to secure the weld. ASSEMBLY LINES FAS - Flexible assembly systems ensure high quality modules even for lower volumes. AAS - Automatic assembly systems produce high volumes of customized modules in fully automatic operation. The optimal assembly line is selected after a technical and qualitative assessment of the customized module according to cost and productivity. SUMIDA flexible connections GmbH is ISO TS 16949 and ISO 14001 certified. If you like to get further information we could provide a presentation about the topics PPAP, IMDS, ROHS/REACH, UL to you. ® PANTA FLEXIBLE MODULES | 22 SUMIDA flexible connections GmbH Agathe-Zeis-Str. 5 · D-01454 Radeberg · Germany Phone +49 3528 404030 · Fax +49 3528 404040 [email protected] · www.sumida-flexcon.com Version 03/2014