Pancon Connectors (shortened to Pancon) was founded in 1968, committed to designing and manufacturing high-quality electronic connectors. The products include IDC series (such as MAS-CON), DIN 41612 series (such as HI-CON), etc. For example, the HI-CON DIN 41612 series is a standard rectangular plug/socket, suitable for 2.54mm or 5.08mm spacing, with a plug-and-pull life of about 400 times. The MAS-CON IDC series can achieve 2.54mm or 3.96mm spacing and supports cable line connections from AWG18 to AWG28. These features demonstrate that Pancon has mature experience and reliability in the field of traditional electrical connectors.
I. Industry Trends and Technical Challenges of Photoelectric Hybrid ConnectorsThe so-called photonic hybrid connector refers to the integration of optical/fiber signal channels and copper wire/current channels in the same connector or a combination of connector systems. It has an increasingly larger application space in high-speed communication, data centers, optical fiber communication, LiDAR, intelligent sensing, unmanned aerial vehicles and autonomous driving systems, and 5G/6G base stations.
This type of connector usually needs to meet the following key conditions:
● Fiber channel requires extremely low loss, good end face polishing, stable insertion and extraction times, and vibration resistance.
The electrical signal channel needs to maintain low contact resistance, high current capacity, and good shielding/anti-interference ability.
In the integrated optoelectronic system, the structure is compact, with strong adaptability to humid and wet/vibration/shock environments, and complex process coordination.
Therefore, for connector manufacturers, shifting from traditional purely electrical connections to photoelectric hybrid connections is not only a change in structural design, but also a significant improvement in aspects such as materials, manufacturing processes, testing and verification, and reliability assessment.
Chapter 2: Domestic Connectors - Analysis of Photonic and Hybrid Connector Layout Based on Pancon ReferenceBased on the existing specifications and characteristics of Pancon, if domestic connectors are to enter the mixed optoelectronic connector market, they can proceed from the following aspects:
Utilize mature experience with electrical connectors to expand to hybrid structures
●Pancon's HI-CON, MAS-CON series already has good insertion and extraction life, standardized spacing, and reliability certification on electrical connectors.
Domestic manufacturers can draw on its stability and standardized process in electrical connections, first do well in the pure electric channel, and then extend to hybrid structures.
In the design, the optical module and the electrical connection module can be arranged in separate areas within the same housing or the same connection system. The copper line path and the optical channel can adopt a separated structure to prevent interference and heat accumulation.
Material and structural design should be optimized for both "light" and "electricity" dual channels.
● Fiber channel requires low thermal expansion, low outgassing, precise face-to-face alignment, and low loss after connector insertion and removal.
●Electrical channels require good electrical conductivity, low contact resistance, high current carrying capacity, and vibration resistance.
●Domestic solutions need to consider: optical channels using precision ceramic/glass components, copper channels using high-performance alloys plus gold plating treatment; the housing material needs to be compatible with optical fiber environment (such as low temperature, high humidity, vibration).
In terms of layout: electrical channels and optical channels should avoid mutual thermal and electromagnetic interference. The structure may adopt shielding, isolation structure, graded sealing, coaxial layout, etc.
Manufacturing process and testing standards need to be upgraded
In electrical connector testing, Pancon already has the specification of "400 cycles of insertion and removal life." When domestic products are expanding to mixed applications, it is also necessary to formulate tests such as "optical channel insertion and removal life + loss change" and "electrical channel insertion and removal life + contact resistance change."
●Mixed connectors also need to undergo optical loss tests (such as insertion loss, return loss), post-vibration loss changes, post-temperature cycle loss changes, contact resistance and voltage resistance changes in the electrical channel, etc.
Strict tolerance control, optical fiber end face polishing and coating control, and reliability control of the optical fiber positioning structure and insertion mechanism are required in the manufacturing process. Domestic manufacturers need to set up corresponding detection equipment and process systems.
In the project phase, clarify with the customer the "specifications of the photoelectric hybrid connector" (such as optical channel insertion loss ≤0.5 dB, return loss ≥…, electrical channel contact resistance ≤… mΩ, lifespan ≥1000 times) and advance in three stages: design process, trial production verification, and mass production verification.
Domestic substitution opportunities and differentiated positioning
Although Pancon is renowned for its electrical connectors, it may not be the core layout in the optoelectronic hybrid field, but its experience in standardization and modularization can serve as a reference.
●Domestic connectors can differentiate themselves in aspects such as "hybrid structure", "local supply chain localization", and "greater flexibility in customization".
Under the trend of "domestic substitution," if it can provide "optical + electrical channel integrated connector" and meet high reliability requirements, it will have a strong competitive advantage.
Cooperating with customers in the early stages of the project (such as samples, verification, and customization of optical channel structures) can gradually promote the layout of domestic connectors in the application of photonic hybrid connections.
The effort of domestic connectors to layout photonic hybrid connections is a process of crossing from "mature electrical connectors" to "optical + electrical integration." Referring to the technical experience of Pancon Connectors' electrical connectors, domestic manufacturers can start from five dimensions of design, materials, technology, testing, and project introduction to gradually advance the research and production of photonic hybrid connectors. Although challenges exist, they also contain huge opportunities: domestically produced connectors have natural advantages in localization of supply chains, customized speed, and flexible solutions. If the three key breakthroughs of "structural integration," "reliability verification," and "production stability" can be successfully achieved, domestic photonic hybrid connectors will win a place in high-growth fields such as communication, data centers, new energy, and intelligent sensing. Welcome to discuss this direction with us and jointly layout the future connector market!
If you are interested in or have procurement needs for domestic alternatives to the brand Pancon Connectors, or if you have production or sales channels for domestic alternatives to this brand of connectors and wish to engage in in-depth cooperation or communication, please contact us through the following methods:
Manager Zhang (18665383950, same WeChat number)We look forward to working together with more industry partners.
