Terminal Blocks - Headers, Plugs and Sockets

Part Number	Description / PDF	Quantity
796858-5 TE Connectivity AMP Connectors	TERM BLOCK PLUG 5POS STR 5MM	270
284514-5 TE Connectivity AMP Connectors	TERM BLOCK HDR 5POS VERT 3.5MM	2629
2350513-5 TE Connectivity AMP Connectors	5POS TB HDR 90 DEG PITCH 5.0 & T	3180
1-282812-0 TE Connectivity AMP Connectors	TERM BLOCK HDR 10POS 90DEG 5MM	0
1986370-3 TE Connectivity AMP Connectors	TERM BLOCK PLUG 3POS 90DEG 3.5MM	0
1546208-4 TE Connectivity AMP Connectors	TERM BLOCK PLUG 4POS STR 5MM	0
1-1986371-2 TE Connectivity AMP Connectors	TERM BLOCK PLUG 12POS 3.5MM	0
1-1546931-0 TE Connectivity AMP Connectors	TERM BLOCK HDR 10POS VERT 5MM	29
796640-5 TE Connectivity AMP Connectors	TERM BLOCK PLUG 5POS STR 5MM	436
2342078-8 TE Connectivity AMP Connectors	8POS HDR ST HT 3.81MM PITCH TL 1	400
284511-2 TE Connectivity AMP Connectors	TERM BLOCK PLUG 2POS STR 3.81MM	168
2318582-4 TE Connectivity AMP Connectors	WIREMATE 2-PIECE 8MM CONN ASSY,	1290
796861-2 TE Connectivity AMP Connectors	TERM BLOCK PLUG 2POS 5.08MM	0
1-1546019-0 TE Connectivity AMP Connectors	TERM BLOCK HDR 10POS VERT 5MM	0
2-1986722-0 TE Connectivity AMP Connectors	TERM BLOCK PLUG 20POS STR 3.81MM	3
2213933-3 TE Connectivity AMP Connectors	SMT TB R/A HEADER, RET, 3.5MM, 3	4748
2342077-5 TE Connectivity AMP Connectors	5POS HDR 90 DEG HT 3.81MM PITCH	600
1986300-3 TE Connectivity AMP Connectors	TERM BLOCK PLUG 3POS STR 5MM	0
2-1546931-4 TE Connectivity AMP Connectors	TERM BLOCK HDR 24POS VERT 5MM	0
1-796634-8 TE Connectivity AMP Connectors	TERM BLOCK PLUG 18POS STR 5.08MM	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