Terminal Blocks - Headers, Plugs and Sockets

Part Number	Description / PDF	Quantity
5431592 Phoenix Contact	TERM BLOCK HDR 5POS VERT 3.81MM	0
1803413 Phoenix Contact	TERM BLOCK HDR 16POS 3.81MM	75800
1876291 Phoenix Contact	TERM BLOCK HDR 5POS 90DEG 3.5MM	601400
1786417 Phoenix Contact	TERM BLOCK HDR 3POS 90DEG 5.08MM	695
1845798 Phoenix Contact	TERM BLOCK HDR 6POS VERT 5MM	0
5452113 Phoenix Contact	TERM BLOCK HDR 4POS VERT 3.81MM	43
1850453 Phoenix Contact	TERM BLOCK HDR 4POS 90DEG 5.08MM	0
5430441 Phoenix Contact	TERM BLOCK HDR 4POS 90DEG 3.5MM	100
1718067 Phoenix Contact	TERM BLOCK PLUG 12POS STR 5MM	36
1757051 Phoenix Contact	TERM BLOCK PLUG 6POS STR 5.08MM	5175
1738898 Phoenix Contact	TERM BLOCK PLUG 22POS STR 3.5MM	17
1804933 Phoenix Contact	TERM BLOCK PLUG 5POS STR 7.62MM	29
1835504 Phoenix Contact	TERM BLOCK PLUG 5POS 90DEG 5MM	124
1943276 Phoenix Contact	TERM BLOCK PLUG 5POS STR 3.81MM	27
1830321 Phoenix Contact	TERM BLOCK HDR 18POS VERT 3.81MM	50100
1851371 Phoenix Contact	TERM BLOCK PLUG 16POS STR 3.81MM	59
1781030 Phoenix Contact	TERM BLOCK PLUG 7POS STR 5.08MM	10
1963434 Phoenix Contact	TERM BLOCK HDR 3POS 90DEG 2.5MM	0
1714964 Phoenix Contact	TERM BLOCK PLUG 6POS STR 3.81MM	89
1863372 Phoenix Contact	TERM BLOCK PLUG 9POS 90DEG 3.5MM	29

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