How can I locate connectors with a good rating on connect/disconnect cycle lifetime? (1000+ cycles)
I've tried searching on google, and I've checked a couple of Molex series I'm familiar with, no luck.
1-row 0.1″ pin spacing connectors with good connect/disconnect cycles
connectordurability
Related Solutions
I designed a product line that used the FFC's and what I found is that long cables (about 12 inches) would tend to work loose in shipping. Basically, there was enough cable flopping in the breeze, with enough mass, that when the box was bumped around there was enough force/torque that it cable could come out of the connector. Fastening the cable down along it's length, so it couldn't flop around so much, helped a lot.
In the same product, we have a small LCD with a short (1 inch) FFC on it. We have never had an issue with this one.
This product line has since been redesigned to eliminate the FFC's (except for the LCD). The FFC's were an expensive mistake for us.
In my experience RCA plugs make a very tight connection, and I expect the resistance to be way less than 50 mΩ, probably near 10 mΩ. Even at 2 times 50 mΩ (you have to count both pin and sleeve) a 500 mA current will cause a 25 mW dissipation, which is more than acceptable.
Matt makes a valid point about mixing them up with audio plugs, though. The wall-wart probably has a DC jack like this
Why not use a socket for that? These are almost exclusively used for power supplies, so there's little chance of confusing them for something else. Sockets for them are readily available.
Best Answer
I can not tell you how to locate these parts, but a quick search on Samtec's site and I was able to find a mechanical test report of 0.100" headers/sockets here: http://www.samtec.com/Documents/WebFiles/TestRpt/TC0733-1424_Reportrev5_elp.pdf
A TSW/BCS or TSM/SSM mating combination with 10u gold plating has been demonstrated to exceed 1000 cycles with minimal contact resistance degradation.