Barrel - Audio Cables

Part Number	Description / PDF	Quantity
10-03200 Tensility International Corporation	CBL ASSEM 3.5MM 3CON R/A M 4.5M	245
10-03199 Tensility International Corporation	CBL ASSEM 3.5MM 3CON R/A M 3M	164
10-03220 Tensility International Corporation	CBL ASSEM 3.5MM 4CON R/A M 3M	50
10-03720 Tensility International Corporation	CBL 3.5MM 3CON M-F 6' SHIELDED	600
10-03202 Tensility International Corporation	CBL ASSEM 3.5MM 3CON M-F 3M	241
10-03408 Tensility International Corporation	CBL ASSY TWIST LOCK F 3.5MM 3CON	597
10-02148 Tensility International Corporation	CBL 3.5MM F-F 28AWG SHLD	377
10-03211 Tensility International Corporation	CBL ASSEM 3.5MM 4CON M-M 3M	123
10-00331 Tensility International Corporation	CBL ASSY 2.5MM SLIM 6' 4C WHT	268
10-03212 Tensility International Corporation	CBL ASSEM 3.5MM 4CON M-M 4.5M	225
10-03749 Tensility International Corporation	CBL 3.5MM 3CON M-M 3' SHIELDED	592
10-03217 Tensility International Corporation	CBL ASSEM 3.5MM 4CON M 3M	472
CA-0843R Tensility International Corporation	CONN CABLE ASSY 3.5MM	0
10-03412 Tensility International Corporation	CBL TWIST LOCK F 3.5MM 3C PNL MN	600
CA-2204 Tensility International Corporation	CABLE ASSY R/A 2.5MM STEREO 6'	734
10-03221 Tensility International Corporation	CBL ASSEM 3.5MM 4CON R/A M 4.5M	235
10-03205 Tensility International Corporation	CBL ASSEM 3.5MM 3CON R/A M-F 3M	235
10-03196 Tensility International Corporation	CBL ASSEM 3.5MM 3CON M 3M	521
10-03209 Tensility International Corporation	CBL ASSEM 3.5MM 3CON F 4.5M	205
10-03752 Tensility International Corporation	CBL 3.5MM 3CON R/A M-M 6' SHIELD	600

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