Terminal Blocks - Headers, Plugs and Sockets

Part Number	Description / PDF	Quantity
1766686 Phoenix Contact	TERM BLOCK HDR 4POS VERT 7.5MM	651
691352510007 Würth Elektronik Midcom	TERM BLOCK PLUG 7POS 5.08MM	160
691701550002B Würth Elektronik Midcom	5.08 MM TERMINAL BLOCK HEADER, H	500
1546931-6 TE Connectivity AMP Connectors	TERM BLOCK HDR 6POS VERT 5MM	1179
0395373006 Woodhead - Molex	TERM BLOCK PLUG 6POS 5.08MM	0
1735866 Phoenix Contact	TERM BLOCK HDR 4POS 90DEG 5.08MM	14
0395355008 Woodhead - Molex	TERM BLOCK HDR 8POS VERT 5.08MM	529
5452215 Phoenix Contact	TERM BLOCK PLUG 4POS STR 5MM	186
1780430000 Weidmuller	TERM BLOCK HDR 4POS 90DEG 5.08MM	104
1014440000 Weidmuller	TERM BLOCK PLUG 8POS STR 5.08MM	72
1731549 Phoenix Contact	TERM BLOCK HDR 8POS VERT 3.5MM	156
OSTV7203251 On-Shore Technology, Inc.	TERM BLOCK HDR 20POS 3.81MM	0
691344410004 Würth Elektronik Midcom	7.62 MM TERMINAL BLOCK PLUG, HOR	200
1809160 Phoenix Contact	TERM BLOCK HDR 11POS 5.08MM	0
1015463 Phoenix Contact	CONN PLUG 3POS 2.5MM	498250
1027613 Phoenix Contact	TERM BLOCK PLUG 11POS 2.54MM	50
EDSTLZ950/4-OE On-Shore Technology, Inc.	TERM BLOCK HDR 4POS 90DEG 5.08MM	0
1982340000 Weidmuller	TERM BLOCK PLUG 5POS 5.08MM	96
1880753 Phoenix Contact	TERM BLOCK PLUG 11POS STR 5.08MM	50
1737822 Phoenix Contact	TERM BLOCK PLUG 3POS 7.5MM	50

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