I'm working on a hobby project, a handwired ultra-low-profile computer keyboard with a 3D-printed case. The USB-C connector on my dev board is only 3mm tall, so it fits within the 4.5~5.0mm of available headroom. However, I need to add a second connector to link the two keyboard halves together, and this is the problem: I can't find a suitable connector that fits inside this volume.
- 4+ contacts, all low power (5V, <500mA)
- Max 5mm height (width up to ~20mm is fine)
- Panel-mount (not PCB-mount)
- Supports some form of strain relief on the plug/free side
Circular connectors don't get this small—including the locking nuts, the smallest I've seen tend to be around 8~10mm dia. Even 2.5mm barrel jacks won't cut it. I also checked out Molex and JST, but the panel-mount options I could find were still around 8mm height minimum. Strain relief is also a concern for these header-style connectors. USB-C actually fits, but I would be using the connector out of spec, and it can't be panel-mounted (the main one only works because of my dev board's mid-mount setup).
Any suggestions? I really didn't expect this to be such a sticking point…