Modular Connectors

Modular Connectors - Plugs

Part Number	Description / PDF	Quantity
19872 Lumberg Automation	RJ45 G-478/2 M	0
TM21CP-88P(13) Hirose	CONN MOD PLUG	0
09451151701 HARTING	CONN MOD PLUG 8P8C SHIELDED	0
SS-39100-029 Stewart Connector	CONN MOD PLUG 8P8C UNSHIELDED	0
PC4D0024-19NX-1-C TE Connectivity Raychem Cable Protection	PC4D0024-19NX-1-C	0
1300520001 Woodhead - Molex	ODVA BULKHEAD PASSTHROUGH RECE	0
MP530-C Panduit Corporation	30 AWG, CATEGORY 5E, UTP MODULAR	0
CAPFCU-B25 Belden	CAT6/6A FIELD CRIMPED PLUG KIT	4297
17-150264 CONEC	PLUG ASSY RJ45 CAT.6A	0
SS-37000-004 Stewart Connector	CONN MOD PLUG 8P8C UNSHIELDED	0
09451251700 HARTING	CONN MOD PLUG 8P8C SHIELDED	0
RTPSA-C Panduit Corporation	SP688 MODULAR PLUG HOUSING, 100	1000
TM21P-88P(13) Hirose	CONN MOD PLUG 8P8C SHIELDED	0
MP44RX-1000S Kycon	MOD PLUG 4P4C-SOLID WIRE/ROUND R	0
1963150000 Weidmuller	CONN MOD PLUG 8P8C SHIELDED	0
CAPFMUL-S1 Belden	CAT6A FIELD PLUG T568A/B LARGE	0
SS-30400-017 Stewart Connector	CONN MOD PLUG 4P4C UNSHIELDED	0
PC4D0024-19NX-4-J TE Connectivity Aerospace Defense and Marine	PC4D0024-19NX-4-J	0
SS-39200-023 Stewart Connector	CONN MOD PLUG 8P8C SHIELDED	0
940-SP-360606-A151 Stewart Connector	CONN MOD PLUG 6P6C SHIELDED	0

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