Barrel - Audio Cables

Part Number	Description / PDF	Quantity
10-03721 Tensility International Corporation	CBL 3.5MM 3CON F 6' SHIELDED	0
10-02844 Tensility International Corporation	CBL ASSY 3.5MM JACK STEREO	270
10-03204 Tensility International Corporation	CBL ASSEM 3CON 3.5MM M-F 6M	0
10-03706 Tensility International Corporation	JACK PNL MNT W/LEAD 3.5MM STEREO	572
10-03229 Tensility International Corporation	CBL ASSEM 3.5MM 4CON F 3M	217
10-03214 Tensility International Corporation	CBL ASSM 3.5MM 4CON R/A M-R/A M	0
10-03724 Tensility International Corporation	CBL 3.5MM 4CON M-F 6' SHIELDED	596
10-02150 Tensility International Corporation	CBL 3.5MM F 28AWG SHLD	266
10-03707 Tensility International Corporation	JACK PNL MNT W/LEAD 3.5MM 4C	568
10-02144 Tensility International Corporation	CBL 2.5MM R/A M 28AWG SHLD	1373
10-02143 Tensility International Corporation	CBL 3.5MM R/A M 28AWG SHLD	446
10-03207 Tensility International Corporation	CBL ASSEM 3CON 3.5MM R/A M-F 6M	0
10-02154 Tensility International Corporation	CBL 3.5MM M-M 28AWG SHLD	208
10-02845 Tensility International Corporation	CBL ASSY 3.5MM JACK 4CON	355
10-00334 Tensility International Corporation	CBL ASSY 2.5MM SLIM 6' MONO WHT	128
10-03403 Tensility International Corporation	CBL ASSY TWIST LOCK M 3.5MM 4CON	330
CA-356CS Tensility International Corporation	CONN CABLE ASSY 3.5MM 6COND 6'	1807
10-00340 Tensility International Corporation	CBL ASSY 2.5MM SLIM 6' 4C BLK	837
CA-2205 Tensility International Corporation	CABLE ASSY STR 3.5MM MONO 6'	2185
10-03411 Tensility International Corporation	CBL TWIST LOCK F 3.5MM 3C PNL MN	599

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