Terminal Blocks - Headers, Plugs and Sockets

Part Number	Description / PDF	Quantity
1792346 Phoenix Contact	TERM BLOCK PLUG 12POS 5.08MM	1276150
1775262001 Weidmuller	TERM BLOCK HDR 5POS 90DEG 5.08MM	0
1002140000 Weidmuller	TERM BLOCK PLUG 7POS 5.08MM	70
1757323 Phoenix Contact	TERM BLOCK HDR 10POS 5.08MM	2950
691307400005 Würth Elektronik Midcom	7.62 MM TERMINAL BLOCK HEADER, V	269
0395337009 Woodhead - Molex	TERM BLOCK PLUG 9POS 5.08MM	425
1571140000 Weidmuller	TERM BLOCK HDR 3POS 90DEG 5MM	200
284516-3 TE Connectivity AMP Connectors	TERM BLOCK HDR 3POS VERT 3.5MM	846
1278040000 Weidmuller	TERM BLOCK PLUG 4POS STR 3.5MM	138
2200244 Phoenix Contact	COMPONENT HOUSING, COLOR: YELLOW	43
XW4N-12D1-S Omron Electronics Components	SOCKET,SINGLE-ROW,,TIN REFLOW,	0
14111213001000 HARTING	TERM BLOCK HDR 12POS VERT 2.54MM	489
2318770-2 TE Connectivity AMP Connectors	WIREMATE 2-PIECE 5MM HDR ASSY, 2	1738
1843787 Phoenix Contact	TERM BLOCK HDR 20POS VERT 3.5MM	67
1835177 Phoenix Contact	TERM BLOCK PLUG 10POS 5.08MM	395
1778030 Phoenix Contact	TERM BLOCK PLUG 7POS STR 5.08MM	228100
1755651 Phoenix Contact	TERM BLOCK PLUG 9POS 90DEG 5MM	0
TBP02P1W-381-04BE CUI Devices	TERMINAL BLOCK, PLUGGABLE, 3.81,	0
1740518 Phoenix Contact	TERM BLOCK HDR 3POS 90DEG 5.08MM	519
1979290000 Weidmuller	TERM BLOCK PLUG 4POS 90DEG 5MM	0

Terminal Blocks - Headers, Plugs and Sockets

1. Overview

Terminal blocks, headers, plugs, and sockets are essential components in electrical and electronic systems for establishing reliable connections between circuits. These devices enable signal transmission, power distribution, and system modularity. Their standardized designs ensure interoperability, scalability, and ease of maintenance in complex systems.

2. Main Types and Functional Classification

Type	Functional Characteristics	Application Examples
Terminal Blocks	Screw/clamp-based connections for high current/ voltage	Industrial control panels, power distribution units
PCB Headers	Pin/grid arrays for board-to-board connections	Embedded systems, Arduino shields
RJ Connectors	Modular jacks for data/telecom signals	Ethernet networks (RJ45), telephone systems (RJ11)
D-Sub Connectors	Multi-pin trapezoidal shells for analog/digital signals	Legacy serial interfaces, industrial sensors
USB Connectors	Hot-pluggable interfaces for power/data	Consumer electronics, peripheral devices

3. Structure and Components

Typical structures include:

Insulating housing (PA66, PBT, or LCP plastics)
Contact elements (phosphor bronze, beryllium copper)
Plating materials (gold, tin, nickel for corrosion resistance)
Actuation mechanisms (screws, spring clamps, or friction fits)
EMI shielding layers (for high-frequency applications)

4. Key Technical Specifications

Parameter	Importance
Current Rating (A)	Determines power handling capacity
Voltage Rating (V)	Defines dielectric strength requirements
Contact Resistance (m )	Impacts signal integrity and power loss
Insertion Loss (dB)	Critical for high-speed data transmission
Mating Cycles	Indicates mechanical durability
Operating Temperature (- C to + C)	Defines environmental tolerance

5. Application Fields

Primary industries include:

Industrial automation (PLCs, HMIs)
Telecommunications (5G base stations, routers)
Consumer electronics (smartphones, wearables)
Medical equipment (imaging devices, patient monitors)
Automotive (EV charging systems, ADAS)

6. Leading Manufacturers and Products

Manufacturer	Representative Product
Phoenix Contact	COMBICON series terminal blocks
TE Connectivity	MICRO MATCH connectors
Molex	SL Series headers
Amphenol	D-Subminiature connectors
Samtec	QTE high-speed socket systems

7. Selection Guidelines

Key considerations:

Electrical requirements (current/voltage levels)
Mechanical constraints (space, vibration)
Environmental factors (temperature, humidity)
Signal integrity needs (frequency, noise rejection)
Cost vs. reliability trade-offs
Compliance with standards (IPC, IEC, UL)

8. Industry Trends

Emerging developments include:

Miniaturization for wearable devices
High-speed connectors for 5G/6G ( 25 Gbps)
Hybrid connectors integrating power/data
Eco-friendly materials (halogen-free, RoHS compliant)
Smart connectors with built-in sensors
Automotive-grade connectors for EVs