Terminal Blocks - Headers, Plugs and Sockets

Part Number	Description / PDF	Quantity
3040261 Phoenix Contact	TERM BLOCK PLUG 2POS STR	491950
1860663 Phoenix Contact	TERM BLOCK HDR 4POS VERT 3.81MM	0
1860549 Phoenix Contact	CONN TERM BLOCK PLUG 2POS 5.08MM	252250
1826979 Phoenix Contact	TERM BLOCK PLUG 2POS 3.81MM	9022450
1847987 Phoenix Contact	TERM BLOCK PLUG 12POS 7.62MM	48
1776605 Phoenix Contact	TERM BLOCK HDR 12POS 5.08MM	115
1842953 Phoenix Contact	TERM BLOCK HDR 12POS 3.81MM	56
1945180 Phoenix Contact	TERM BLOCK HDR 11POS VERT 3.5MM	18550
1912362 Phoenix Contact	TERM BLOCK PLUG 9POS 90DEG 5MM	36
1984073 Phoenix Contact	TERM BLOCK PLUG 8POS 3.5MM	27523000
1845001 Phoenix Contact	TERM BLOCK HDR 30POS VERT 2.54MM	0
1863165 Phoenix Contact	TERM BLOCK PLUG 3POS 90DEG 3.5MM	0
1851575 Phoenix Contact	TERM BLOCK HDR 4POS VERT 3.81MM	0
1778861 Phoenix Contact	TERM BLOCK PLUG 5POS STR 2.5MM	373
1706888 Phoenix Contact	TERM BLOCK HDR 12POS 3.81MM	29
1777332 Phoenix Contact	TERM BLOCK PLUG 7POS STR 5.08MM	2
1828579 Phoenix Contact	TERM BLOCK PLUG 10POS 3.81MM	50
1922585 Phoenix Contact	TERM BLOCK HDR 4POS VERT 10.16MM	50
1966143 Phoenix Contact	TERM BLOCK PLUG 7POS STR 3.5MM	50
1912265 Phoenix Contact	TERM BLOCK PLUG 10POS STR 5.08MM	17

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