Terminal Blocks - Headers, Plugs and Sockets

Part Number	Description / PDF	Quantity
3210855 Phoenix Contact	TERM BLOCK PLUG 1POS STR	0
2648650000 Weidmuller	TERM BLK HDR 4POS 180DEG 5.08MM	235250
796638-8 TE Connectivity AMP Connectors	TERM BLOCK HDR 8POS 90DEG 5.08MM	0
1714346 Phoenix Contact	TERM BLOCK PLUG 9POS STR 7.62MM	8
1863068 Phoenix Contact	TERM BLOCK PLUG 8POS 3.5MM	50
691363310007 Würth Elektronik Midcom	3.81 MM TERMINAL BLOCK PLUG, HOR	246
TBP02R1W-381-03BE CUI Devices	TERMINAL BLOCK, PLUGGABLE, W SCR	272
1845374 Phoenix Contact	TERM BLOCK HDR 12POS VERT 5.08MM	0
691386700008 Würth Elektronik Midcom	TERM BLOCK HDR 8POS VERT 5MM	0
0395337012 Woodhead - Molex	TERM BLOCK PLUG 12POS 5.08MM	429
1923759 Phoenix Contact	TERM BLOCK HDR 2POS 90DEG 5MM	282
1790535 Phoenix Contact	TERM BLOCK PLUG 14POS STR 3.5MM	28
1953716 Phoenix Contact	TERM BLOCK HDR 4POS 90DEG 3.5MM	382
1982920000 Weidmuller	TERM BLOCK PLUG 5POS 5.08MM	8448
1835494 Phoenix Contact	TERM BLOCK PLUG 4POS 90DEG 5MM	42
1762509 Phoenix Contact	TERM BLOCK HDR 32POS 5.08MM	85
1838420000 Weidmuller	TERM BLOCK HDR 23POS VERT 5.08MM	50
691343410005 Würth Elektronik Midcom	7.62 MM TERMINAL BLOCK PLUG, HOR	120
0395026002 Woodhead - Molex	TERM BLOCK HDR 2POS 90DEG 3.5MM	3652
1289550000 Weidmuller	TERM BLOCK HDR 24POS 90DEG 3.5MM	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