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Board to Board Connector
Industrial, IT Datacom
The CONSHARE 0.50mm Pitch Floating Board-to-Board Male Header is engineered for applications where PCB alignment cannot be guaranteed with absolute precision. Unlike standard BTB connectors that require near-perfect board registration, this floating design incorporates a compliant contact mechanism that actively compensates for positional deviations during assembly and throughout the product’s operational life.
This vertical SMT header delivers a 10.0mm stacking height and is available in 30-pin (2×15) and 80-pin (2×40) configurations, with additional pin counts available upon request. The 3µ" gold plating over a 50µ" nickel underplate ensures reliable signal integrity in environments ranging from –40°C to +125°C.
Built for engineers who refuse to compromise on connection reliability, this connector addresses the mechanical realities of modern PCB manufacturing—where board warpage, placement tolerances, and thermal expansion can compromise standard interconnects.
Traditional board-to-board connectors assume perfect alignment between mating boards. In reality, PCB manufacturing tolerances, automated pick-and-place variations, and thermal expansion during operation create cumulative positional errors that can exceed 0.3mm. When rigid connectors are forced to accommodate these misalignments, the result is:
Stressed solder joints – leading to premature failure in the field
Reduced production yield – boards rejected during assembly due to mating difficulties
Contact fretting – microscopic wear from vibration that degrades plating and increases contact resistance
Intermittent connections – the hardest failure mode to diagnose
The CONSHARE floating header incorporates a spring-like contact suspension that allows the housing to move laterally and longitudinally relative to the PCB terminations. This elasticity absorbs misalignment during automated assembly while maintaining consistent contact force across the full mating interface.
Key benefit for your production line: When using multiple connectors per board pair—common in modular designs with separate I/O, processor, and power boards—the cumulative misalignment between connectors can make rigid connectors impractical. The floating design enables pick-and-place processes to proceed without the need for ultra-precision alignment equipment, reducing manufacturing costs and improving throughput.
Selection Factor | 30-Pin (2×15) | 80-Pin (2×40) |
|---|---|---|
Typical Applications | Sensor interfaces, control modules, compact IoT devices | High-density computing, automotive ECUs, industrial controllers |
PCB Space | Compact footprint – ideal for space-constrained designs | Larger footprint – maximizes signal density per board area |
Signal Routing | Suitable for lower I/O count applications | Enables complex multi-signal routing with dedicated power/signal segregation |
Mechanical Stability | Lower insertion force, easier manual mating | Higher retention force – better resistance to shock and vibration |
Best Fit For | ADAS sensors, LiDAR modules, camera systems | Battery management systems (BMS), onboard chargers (OBC), PLC modules |
The 30-pin variant is the choice for applications where PCB real estate is at a premium but reliability cannot be sacrificed. With a compact board footprint, this configuration integrates seamlessly into:
Automotive camera modules and radar sensors – where space is measured in millimeters and vibration resistance is non-negotiable
LiDAR equipment – requiring stable high-speed connections in thermally challenging environments
Portable and handheld devices – where board stacking heights must remain consistent despite manufacturing tolerances
The reduced pin count also means lower insertion forces, facilitating easier mating during final assembly—a practical advantage when manual assembly is involved.
The 80-pin variant supports complex, high-I/O-count designs where signal integrity and density are paramount. This configuration is well-suited for:
Electronic Control Units (ECUs) – managing multiple sensor inputs and actuator outputs simultaneously
Industrial PLCs and controllers – where 24/7 operation demands connections that withstand thermal cycling and mechanical stress
Battery management systems and onboard chargers – requiring both signal and power integrity in automotive-grade applications
The higher pin count also enables better signal segregation—dedicated pins for power, ground, and high-speed data can be distributed to minimize crosstalk and improve overall system performance.
The connector housing is molded from liquid crystal polymer (LCP), a material chosen specifically for its exceptional thermal and mechanical properties. LCP maintains dimensional stability at elevated temperatures, ensuring consistent contact alignment even after repeated thermal cycling. The UL94V-0 flammability rating provides an additional layer of safety for applications where fire resistance is mandated.
The 3µ" gold plating over a 50µ" nickel underplate is not a cosmetic choice—it serves three critical functions:
Oxidation resistance – gold’s inert nature prevents contact degradation in humid or corrosive environments
Low and stable contact resistance – maintaining signal integrity over thousands of mating cycles
Fretting corrosion protection – the nickel underplate provides a barrier against wear-through, even under vibrational stress
For applications requiring extended durability, alternative gold plating thicknesses (1µ", 5µ", 10µ", 15µ", 30µ") are available, allowing designers to match plating specification to expected mating cycle requirements and environmental conditions.
This wide operating range covers the full spectrum of industrial and automotive requirements. Whether deployed in engine compartments, industrial ovens, or cold-start automotive environments, the connector maintains consistent electrical and mechanical performance.
Modern vehicles integrate dozens of electronic modules, each requiring reliable board-to-board connections. The CONSHARE floating header is particularly well-suited for:
Advanced Driver Assistance Systems (ADAS) – camera, radar, and LiDAR modules require stable connections despite vehicle vibration and temperature extremes
Infotainment and navigation systems – high pin counts support the complex signal routing required for displays, audio, and connectivity modules
Powertrain control units – where proximity to heat sources demands materials that maintain performance at elevated temperatures
Factory automation equipment operates 24/7 in environments with vibration, temperature variation, and electromagnetic interference. The floating design provides:
Resistance to mechanical shock – protecting connections in robotics and automated machinery
Tolerance for thermal expansion – accommodating the different coefficients of thermal expansion between PCB materials and connector housings
Reliability in high-vibration environments – preventing contact fretting that leads to intermittent failures
In embedded systems and medical equipment, space constraints and reliability requirements converge:
Industrial PCs and embedded controllers – modular board designs benefit from floating connectors that tolerate assembly variations
Medical monitoring and imaging equipment – where connection failures are simply not an option
The floating mechanism provides compensation for positional deviations in both X and Y axes, accommodating the cumulative tolerances typical of automated PCB assembly processes. This eliminates the need for ultra-precision placement equipment and reduces assembly-related rejects.
Yes. The vertical SMT design is fully compatible with standard pick-and-place processes. The floating mechanism actually improves assembly yield by compensating for the minor placement variations that inevitably occur during high-speed automated assembly.
The PCB layout should follow the recommended footprint dimensions with a board tolerance of ±0.05mm. The floating design accommodates deviations beyond this tolerance, but proper footprint design ensures optimal solder joint formation and mechanical stability.
3µ" gold provides an optimal balance between cost and performance for most industrial and automotive applications. For higher mating cycle requirements or more aggressive environments, thicker gold plating (5µ" to 30µ") is available. The nickel underplate (50µ" minimum) provides the corrosion barrier that makes the gold plating effective.
The connector withstands peak reflow temperatures of 265°C for up to 40 seconds, compatible with standard lead-free soldering profiles. The LCP housing maintains dimensional stability throughout the reflow process.
Yes. The CONSHARE floating BTB series supports multiple pin count configurations, including 20-pin (2×10), 40-pin (2×20), 50-pin (2×25), 60-pin (2×30), 100-pin (2×50), and 120-pin (2×60). Contact CONSHARE for custom configurations or stack height requirements.
CONSHARE brings decades of precision interconnect engineering to every product. Our floating BTB connectors are manufactured to exacting standards, with:
Rigorous quality control – each production batch undergoes salt spray testing (5% concentration, 35±2°C, 8 hours minimum) to verify corrosion resistance
Material traceability – full documentation of housing materials, contact alloys, and plating specifications
Technical support – engineering assistance for footprint design, assembly process optimization, and application-specific customization
Whether you are designing the next generation of automotive safety systems, industrial automation equipment, or high-reliability embedded computing platforms, CONSHARE delivers the interconnect solutions you can depend on.
CONSHARE – Precision Interconnect. Engineered for Reliability.
For technical specifications, custom configurations, or application engineering support, please contact our sales team.
