Modular Connectors

Modular Connectors - Plugs

Part Number	Description / PDF	Quantity
1608100 Phoenix Contact	CONN MOD PLUG 8P4C SHIELDED	471
1656725 Phoenix Contact	CONN MOD PLUG 8P8C	3203041
09454001100 HARTING	CONN MOD PLUG 8P4C SHIELDED	11
09352210401 HARTING	CONN MOD PLUG 8P4C SHIELDED	8
943-SP-370808SM2-A233 Stewart Connector	CONN MOD PLUG 8P8C SHIELDED	683
TM31P-TM-88P Hirose	CONN MOD PLUG 8P8C	81
0950432891 Woodhead - Molex	CONN MOD PLUG 8P8C SHIELDED	1370
E300502 010S1 Belden	INDUSTR PLUG KIT CAT5E FTP	0
PXM6034/B Bulgin	CONN MOD PLUG 8P8C SHIELDED	35
N030-100 Tripp Lite	CONN MOD PLUG 8P8C UNSHLD 1=100	1321900
TM21P-88P Hirose	CONN MOD PLUG 8P8C SHIELDED	27
1518090000 Weidmuller	RJ45 PLUG, NO TOOLS REQUIRED, AN	838
09451511520 HARTING	CONN MOD PLUG 8P8C SHIELDED	318
1012170000 Weidmuller	CONN MOD PLUG 8P8C SHIELDED	9
100028C Platinum Tools	CONNECTOR EZEX44 (CAT6 23 AWG),	0
1301980178 Woodhead - Molex	RJ45-PLUG; MOD PLUG 8 POSITION 8	25
32-5956UL Vitelec / Cinch Connectivity Solutions	CONN MOD PLUG 6P6C UNSHIELDED	5345
PXP6034/B Bulgin	CONN MOD PLUG 8P8C SHIELDED	21
0449150022 Woodhead - Molex	CONN MOD PLUG 8P8C SHIELDED	1773
937-SP-301010R Stewart Connector	CONN MOD PLUG 10P10C UNSHIELDED	7063

Modular Connectors - Plugs

1. Overview

Modular connectors-plugs are standardized electro-mechanical interfaces enabling rapid connection/disconnection of electronic devices. Defined by international standards (IEC 60603, TIA/EIA-568), these components form the backbone of modern communication infrastructure. Their hot-swappable design ensures system flexibility while maintaining signal integrity in applications ranging from telecommunication to industrial automation.

2. Main Types & Functional Classification

Type	Functionality	Applications
RJ11	6-position 2-conductor	Traditional telephone systems
RJ45	8-position 8-conductor (Cat6/8)	Ethernet networks (10/100/1000 Mbps)
USB Type-A	Rectangular 24-pin	Host/device connectivity (USB 3.2 Gen2)
USB Type-C	Oval 24-pin reversible	Power Delivery (100W), Thunderbolt 4
HDMI Type-A	19-pin digital video/audio	4K/8K display interfaces

3. Structure & Composition

Typical modular plugs feature:

Contact points: Phosphor bronze with gold plating (30-50 m)
Insulation: High-temperature thermoplastics (LCP/PBT)
Shell: Zinc alloy or reinforced polymer
Retention mechanism: Spring-loaded latches (3.5N typical force)

Advanced designs incorporate EMI shielding (Mu-metal) and strain relief boots for 5000+ mating cycles.

4. Key Technical Specifications

Parameter	Value Range	Critical Importance
Rated Voltage	50-600V AC	Electrical safety compliance
Contact Resistance	5-20m	Signal integrity maintenance
Insulation Resistance	100M -10G	Prevent current leakage
Operating Temp	-55 C to +125 C	Environmental reliability
Mating Cycles	1,500-10,000	Product longevity

5. Application Fields

Primary industries include:

Telecommunications: 5G base stations, VoIP systems
Consumer Electronics: Smartphones, VR headsets
Industrial Automation: PLC interfaces, sensor networks
Medical Equipment: MRI scanners, patient monitors
Automotive: Onboard diagnostics (OBD-II), infotainment

Typical devices: Network switches, PoE-powered devices, USB-C docking stations.

6. Leading Manufacturers & Products

Manufacturer	Product Example	Key Features
TE Connectivity	DB115X Series	10G Ethernet, PoE++ support
Amphenol	USB6781-C	USB4 Gen3, 40Gbps data rate
Molex	705456 Series	Automotive-grade HDMI (Type-E)
Samtec	ZSE2-10-S-8C	High-speed RJ45 with integrated magnetics

7. Selection Guidelines

Key selection criteria:

Match interface standard to protocol requirements (e.g., USB4 vs. Thunderbolt 4)
Evaluate current carrying capacity (1.5A-5A per pin)
Environmental compliance (IP67, RoHS)
Termination type (PCB mount vs. cable)
EMI/RFI shielding effectiveness
Cost vs. longevity trade-offs

Case study: Selecting USB Type-C over Micro USB for new IoT devices due to 10x durability rating and reversible design.

8. Industry Trends

Emerging developments:

Optical modular connectors for 400Gbps+ data rates
Hybrid connectors integrating power/data transmission
Nanocoatings for IP68-rated industrial connectors
Smart connectors with embedded ID chips (USB-IF Authentication)
Recyclable polymer composites for eco-friendly designs