Barrel - Audio Cables

Part Number	Description / PDF	Quantity
10-03228 Tensility International Corporation	CBL ASSEM 4CON 3.5MM R/A M-F 6M	0
10-02136 Tensility International Corporation	CBL 3.5MM M-F 28AWG SHLD	1849
CA-2201 Tensility International Corporation	CABLE ASSY STR 2.5MM MONO 6'	8472
10-03198 Tensility International Corporation	CBL ASSEM 3CON 3.5MM M 6M	0
10-02153 Tensility International Corporation	CBL 3.5MM M-M 28AWG SHLD	1296
10-02130 Tensility International Corporation	CBL 2.5MM R/A M-M 28AWG SHLD	180
CA-254S-M/M Tensility International Corporation	CONN CABLE ASSY 2.5MM 4COND 6'	43
10-02152 Tensility International Corporation	CBL 3.5MM M-M 28AWG SHLD	989
10-03192 Tensility International Corporation	CBL ASSEM 3CON 3.5MM M-M 6M	0
10-00344 Tensility International Corporation	CBL ASSY 3.5MM SLIM 6' MONO BLK	230
10-02045 Tensility International Corporation	CBL 3CON 3.5MM PLUG SHLD 6' BIO	112
10-03194 Tensility International Corporation	CBL ASSM 3.5MM 3CON R/A M-R/A M	143
10-03195 Tensility International Corporation	CBL ASSM 3CON 3.5MM R/A M-R/A M	0
CA-254CS-M/M Tensility International Corporation	CONN CABLE ASSY 2.5MM 4COND 6'	0
10-03216 Tensility International Corporation	CBL ASSM 4CON 3.5MM R/A M-R/A M	0
10-02155 Tensility International Corporation	CBL 3.5MM M-M 28AWG SHLD	608
10-02140 Tensility International Corporation	CBL 3.5MM R/A M TO 3.5MM F SHLD	0
CA-254CS Tensility International Corporation	CONN CABLE ASSY 2.5MM 4COND 6'	0
10-02843 Tensility International Corporation	CBL ASSY 3.5MM JACK MONO	385
10-03219 Tensility International Corporation	CBL ASSEM 4CON 3.5MM M 6M	0

Barrel - Audio Cables

1. Overview

Barrel-style audio cables are cylindrical connectors with a central pin and surrounding sleeve, designed for analog audio signal transmission. They are widely used in consumer electronics, professional audio equipment, and industrial systems. Their compact design and reliable signal integrity make them essential for audio connectivity in modern technology.

2. Main Types and Functional Classification

Type	Functional Features	Application Examples
3.5mm Barrel (TRS)	Balanced stereo audio transmission with tip-ring-sleeve configuration	Smartphones, headphones, portable audio devices
6.35mm Barrel (1/4")	High-fidelity audio for professional instruments and studio gear	Electric guitars, amplifiers, mixing consoles
RCA Barrel	Unbalanced analog audio/video signal transmission	Home theaters, DVD players, AV receivers
XLR Barrel (Mini)	Balanced microphone-level signals with locking mechanism	Professional lavalier microphones, broadcast equipment
Fiber Optic Barrel	Digital audio transmission via light pulses	Home theaters, digital audio interfaces

3. Structure and Composition

A typical barrel audio cable assembly includes:

Conductor: Oxygen-free copper (OFC) or silver-plated copper for low resistance
Insulation: Polyethylene or Teflon dielectric material
Shielding:Braided copper mesh + aluminum Mylar foil (100% coverage)
Contact Plating: Gold-plated brass or phosphor bronze contacts (10-30 m thickness)
Outer Jacket: PVC or thermoplastic elastomer (TPE) for flexibility

4. Key Technical Specifications

Parameter	Importance
Conductor Material (e.g., OFC, Silver-Plated)	Determines signal clarity and resistance (0.05-0.2 /m typical)
Shielding Effectiveness (SE)	Measures EMI/RFI protection (60-100dB @ 100MHz)
Frequency Response	Defines audio bandwidth (20Hz-20kHz standard, up to 40kHz for Hi-Res)
Impedance Matching	Ensures signal integrity (75 for RCA, 45-150 for XLR)
Insertion Loss	Signal attenuation metric (<0.5dB @ 10kHz for premium cables)
Durability (Mating Cycles)	Connector lifespan (1,000-10,000 cycles rating)

5. Application Fields

Consumer Electronics: Headphones, gaming headsets, portable speakers
Professional Audio: Studio monitors, PA systems, live sound equipment
Automotive: In-dash audio systems, hands-free calling interfaces
Medical: Hearing aids, diagnostic audio equipment
Industrial: Machine-to-machine audio communication systems

6. Leading Manufacturers and Products

Manufacturer	Representative Product
Audio-Technica	AT-BARREL-PRO - 6N oxygen-free copper cables with dual shielding
Belkin	Studio Pro 3.5mm - Gold-plated connectors, 98% braided shield
Monster	PowerPlay HD - 24K gold contacts with nitrogen-injected dielectric
Neutrik	NCJ6FX-B - XLR barrel connectors with nickel-plated brass construction
Sony	Premium Balanced Cable - 40kHz frequency response for Hi-Res audio

7. Selection Recommendations

Consider these factors when selecting barrel audio cables:

Signal Type: Balanced (TRS/XLR) vs. unbalanced (RCA)
Environmental Stress: Exposure to bending (flex life rating), temperature (-20 C to 70 C typical)
Impedance Matching: Critical for long cable runs (>5m) to prevent signal degradation
Termination Type: Soldered vs. crimp-style connectors for mechanical reliability
Compliance Standards: RoHS, REACH, and UL certifications for safety requirements

8. Industry Trends

Key developments shaping the barrel audio cable market:

Transition to hybrid cables integrating USB-C/Thunderbolt with analog barrels
Nano-coating technologies for IP67-rated waterproof audio assemblies
Biodegradable TPE jackets addressing environmental concerns
Smart cables with embedded chips for signal equalization and authentication
Miniaturization trend: 2.5mm barrels gaining traction in wearable devices