Flat Cable Connectors

Flat cable connectors are critical components in modern electronic systems, offering a high-density, efficient solution for data and power transmission. Designed for environments where space is constrained, and high-performance signal integrity is essential, these connectors address specific technical challenges faced by engineers, designers, and manufacturers. 

Material Options

PBT (Polybutylene Terephthalate), Nylon, Thermoplastic Elastomers, Gold/Nickel-Plated Contacts

Cable Diameter Range

0.5 mm to 10 mm (varies based on connector design)

Temperature Range

-40°C to +125°C (dependent on material and application)

Load Capacity

Up to 10A per contact (depending on connector and cable type)

Vibration Resistance

Rated for continuous vibration up to 30g (can be higher for specific designs)

Product Description

The primary technical advantage of flat cable connectors lies in their space-saving design. Traditional round connectors require larger cable diameters, often making them impractical for applications with limited space. Flat cables, however, have a low profile, allowing them to be routed efficiently in confined spaces while maintaining a robust electrical connection. This characteristic is particularly valuable in applications such as portable electronics, where minimizing the overall footprint is critical without compromising the quality of the connection. 

Corrosion Resistance

Gold and silver-plated contacts, corrosion-resistant housing materials for exposure to moisture, salts

EMI Shielding

Optional shielded variants with copper or aluminum foil and grounding systems

Mounting Options

Through-hole, surface-mount, vertical, horizontal, or custom mounting configurations

Compliance Standards

RoHS, UL, IEC, ISO 9001 Certified (standards vary by application)

Custom Features

Custom pitch sizes, locking mechanisms, polarized designs, and cable lengths

UV Resistance

UV-stabilized materials for outdoor and exposed applications

Fire Resistance Rating

UL 94-V0, V1, or V2 (depending on insulation material)

Chemical Resistance

Resistant to common industrial chemicals (e.g., oils, fuels, solvents) and exposure to harsh environments

Thermal Expansion Tolerance

Low coefficient of thermal expansion (CTE) for stable performance across temperature variations

Dynamic Load Testing

Tested for up to 10 million flex cycles with stable electrical performance under dynamic loads

Precision Tolerances

±0.1mm (standard tolerance), can be customized for high-precision applications

Technical Advantages

Flat cable connectors are engineered to ensure superior signal integrity, which is vital in high-speed data transmission applications. Their parallel arrangement of conductors reduces the amount of electromagnetic interference (EMI) and crosstalk between adjacent lines. The close-pitch design of the pins ensures minimal signal degradation, making them ideal for high-frequency signals in environments such as telecommunications and data centers. Additionally, advanced shielding techniques can be implemented to further enhance the protection against external noise and ensure stable performance even at high data rates. 

Flat cable connectors are often subjected to demanding operational conditions, including high vibration, temperature extremes, and exposure to corrosive substances. These connectors are designed with materials that ensure long-term reliability in such environments. High-performance plastics, such as thermoplastic elastomers and PBT (polybutylene terephthalate), provide resistance to high temperatures and chemical exposure, while gold-plated contacts minimize wear and corrosion. The durability of these connectors helps to extend the life cycle of the equipment they support, reducing the need for maintenance and replacement in harsh conditions like automotive, aerospace, and industrial control systems. 

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Industry Applications

Semiconductor Manufacturing

Facilitates high-frequency signal transmission between semiconductor test equipment, wafer handling systems, and process chambers. 

High-Speed Computing

Ensures reliable interconnects between processors, memory modules, and peripheral components in supercomputers and workstations. 

Military Avionics

Supports data and power connections in avionics systems, radar arrays, and flight control units, ensuring stability in extreme conditions. 

Electric Vehicles (EVs)

Used for high-current connections in battery packs, power distribution units, and charging systems within electric vehicles. 

Test and Measurement Equipment

Provides stable, low-resistance connections for signal acquisition and analysis in lab equipment and field devices. 

Smart Grids

Used in advanced metering infrastructure (AMI) and grid control systems for real-time data transmission and power management. 

High-vibration and Mechanical Stress Resistance

Flat cable connectors are often used in systems subject to continuous movement or vibration, such as automotive or industrial applications. The design of these connectors includes features like secure locking mechanisms, vibration-resistant latching systems, and strain-relief designs to ensure mechanical stability even under dynamic conditions. 

Flat cable connectors are designed with precision-engineered contact points to minimize contact resistance, which is critical for reliable and efficient power delivery. The contacts are often constructed with materials like gold or silver to reduce oxidation and ensure low-resistance connections over time. 

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How do Frigate’s flat cable connectors ensure long-term reliability in harsh industrial environments?

Frigate’s flat cable connectors utilize high-durability materials like PBT and high-temperature-resistant thermoplastics, along with gold-plated contacts to withstand extreme temperatures, vibration, and corrosive conditions in industries like automotive and aerospace. 

What measures does Frigate take to minimize signal degradation in high-speed applications?

Frigate employs precise manufacturing techniques to optimize the conductor layout and pitch size, ensuring reduced crosstalk and minimized electromagnetic interference (EMI) for applications requiring high-speed data transmission, such as telecommunications and data centers. 

How do Frigate’s flat cable connectors handle high-current demands in power distribution systems?

The connectors are designed with low-resistance gold-plated contacts and heavy-duty insulation, enabling them to handle high-current applications while minimizing heat buildup, making them ideal for use in power panels and high-power equipment. 

What customization options does Frigate offer for flat cable connectors in specialized systems?

Frigate offers customizable pin counts, connector pitches, and locking mechanisms to meet the unique needs of specialized systems, ensuring a secure and reliable connection for specific requirements in sectors like robotics, military, and medical devices. 

How does Frigate ensure the performance of flat cable connectors in military-grade systems?

Frigate’s flat cable connectors are built to meet rigorous military standards, with features such as high vibration resistance, rugged insulation materials, and secure latching systems, ensuring reliable performance in demanding conditions like extreme temperatures and mechanical stress. 

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LOCATIONS

Global Sales Office

818, Preakness lane, Coppell, Texas, USA – 75019

Registered Office

23, 6th West Street, Balaji Nagar, Kattur,  Pappakuruchi, Tiruchirappalli-620019, Tamil Nadu, India.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ

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Flat Cable Connectors

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