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Electronic Connectors: Types, Terminology and Termination Methods

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Introduction

A description of the types of electrical connectors with a list of recommended manufacturers

You will learn:

  • What are Electronic Connectors?
  • Terminology Used with Electronic Connectors
  • Types of Electronic Connectors
  • Electronic Connector Termination Methods
  • And Much More…
Electronic Connectors

Chapter 1: Understanding Electronic Connectors

Electronic connectors are essential devices used to link electronic circuits. They play a crucial role in the assembly, installation, and power supply of electrical devices. These components are pivotal in a range of applications, including industrial equipment, consumer electronics, communication systems, and household appliances. Often underestimated, connectors are vital in ensuring that electronic products operate effectively. While some connectors are designed for permanent connections, the majority are intended to be temporary and easily detachable.

An electrical connector comprises two primary parts: the contacts and the housing, commonly known as plugs or receptacles. The housing secures the terminals, maintaining steady connections and providing insulation to prevent unwanted interactions with other electronic elements, thus avoiding short circuits. Plugs and receptacles shield the terminals from the environment and are typically constructed from insulating materials like molded plastics or ceramics.

Depending on the specific application, additional features may be incorporated into a connector. Keyed connectors are designed to fit in a singular orientation to prevent mismatched connections. Some connectors are equipped with locking mechanisms to avoid accidental disconnection. There are also connectors that are meticulously sealed to function efficiently in underwater conditions.

Connector terminals are the contact pins that create an uninterrupted pathway for electrical current to traverse between circuits. These are crafted from conductive materials, including brass, phosphor bronze, beryllium copper, and high-copper alloys.

Chapter 2: Terminologies Used in Electronic Connectors

Understanding the terminology associated with electronic connectors is essential for selecting the right component for your electronic systems. This terminology covers the key properties, construction features, and performance metrics that define connector types and compatibility. Knowledge of these electronic connector terms aids in design decisions, procurement, and troubleshooting for a broad range of applications in electrical engineering, electronics assembly, and industrial automation.

Gender

For electronic connectors, gender is a foundational classification used to differentiate mating connectors—those that fit together based on size, shape, and pin configuration. The plug or male connector contains pins (also called blades or contacts), designed to insert into a female connector, which features a receptacle, jack, or socket with mating contacts. Female connectors have socket holes with terminals attached to conductors, wires, or cables. When the male connector’s pins are inserted into the female jack or socket, they complete the electrical signal path or power connection. Correct selection of connector gender ensures reliable, secure mating and electrical integrity across a wide range of electronic devices and PCB (printed circuit board) assemblies.

Gender of D-sub Connector

Keying

Keying is a critical design feature in electronic connectors aimed at preventing incorrect mating, which could cause electrical failures or mechanical damage. Keying involves unique physical elements—such as keys, keyways, or notches—that make it physically impossible to mate connector pairs in the wrong orientation. This is especially important in multi-way or symmetrical connectors where misalignment could damage components or lead to short circuits. Proper keying ensures connector compatibility and enhances reliability in data, signal, and power connectivity.

Keying

Locking Mechanisms

Locking mechanisms secure mated connectors, preventing accidental disconnection that could disrupt an electronic system. Locking methods include push-pull connectors, bayonet couplings, and fine thread screw couplings, each chosen based on application needs. These mechanisms offer vibration resistance, mechanical retention, and environmental sealing for connectors exposed to demanding industrial, automotive, or aerospace environments. Selecting the right locking feature is crucial in preventing signal loss and maintaining electrical continuity.

Number of Contacts

The number of contacts specifies the total number of pins or terminals that establish individual electrical connection points within a single connector. This value varies widely, from simple 2-pin connectors used for power or signal, up to advanced multi-pin connectors exceeding 200 contacts for high-density circuit applications. The contact count is determined by the device requirements, signal complexity, and interface standard, influencing connector size, footprint, and signal routing capabilities.

Contact Pitch

Contact pitch, or simply pitch, describes the center-to-center spacing between adjacent pins or terminals of a connector, typically measured in millimeters or inches. Contact pitch impacts connector compatibility with PCBs and cable harnesses, affecting signal integrity and miniaturization. Larger pitches allow greater voltage isolation, reducing risk of electrical arcing (when current jumps between too-close pins), while smaller pitches enable high-density layouts in space-constrained designs. Accurate specification of contact pitch is vital in electronic connector selection and assembly for consumer electronics, industrial controls, and communications equipment.

A larger pitch means fewer terminals per connector area, which decreases the risk of arc-over between pins. Careful calculation of contact pitch during electrical connector assembly ensures optimal electrical performance and design compatibility.

Contact Pitch

Pin Numbering

Pin numbering is the standardized method for identifying each terminal or pin within an electronic connector. Numbering schemes—such as left-to-right, top-to-bottom, or specific industry conventions—streamline wire routing and prevent wiring errors, critical in complex multi-pin connectors and custom cable assemblies. Consistent pin identification is essential for schematic diagrams, connector documentation, and successful harness manufacturing for automotive wiring, industrial systems, and PCB layouts.

Pin Numbering

Pin Sequence

The pin sequence of an electronic connector establishes the order in which individual contacts make electrical contact during mating. This arrangement is engineered to prioritize the engagement of ground or shield contacts before signal or power pins, thereby minimizing the risk of device damage from stray voltages or static discharge. Specifying pin sequence is especially relevant for high-speed data, signal, and power connectors used in sensitive instrumentation, computer hardware, and telecommunications infrastructure.

Mating Cycles

Mating cycles define connector durability, referring to the number of times a connector can be properly connected and disconnected without mechanical or electrical failure. Different connector types—such as USB, FFC (Flat Flexible Cable), and FPC (Flexible Printed Circuit) connectors—offer varying mating cycle ranges based on their material quality, terminal plating, thickness, and mating style (e.g., snap-fit, lever lock). High-mating-cycle connectors are essential for test equipment, consumer electronics, and devices requiring frequent reconnections, while lower cycle ratings may be suitable for permanent or infrequent connections.

Mounting

Mounting refers to how an electronic connector is attached to a device or circuit board. Common mounting types include PCB (through-hole or surface-mount), edge mount, panel mount, and cable mount. Proper mounting impacts connector strength, ease of assembly, electrical performance, and field serviceability. For circuit board connectors, PCB mounting standards ensure reliable solder connections and electrical integrity. Panel and chassis mounts are essential in industrial enclosures, aerospace, and telecommunications equipment.

Termination

Termination is the process of electrically connecting wires to a connector’s contact points. Common termination methods include crimping, soldering, and screw terminals. Each method offers different advantages regarding mechanical strength, reliability, and field-serviceability. Choosing the proper termination technique is critical in ensuring signal integrity, consistent contact resistance, and safe modular wiring in cable assemblies, control panels, and harness fabrication.

Strain Relief

Strain relief describes the mechanical support structures, such as fittings or bushings, that dissipate forces acting on an electronic connector or cable assembly. Effective strain relief prevents cable flexing, pull-out, or twisting forces from transferring directly to the terminals, which can cause intermittent electrical contact or conductor breakage. This feature is indispensable in industrial automation, robotics, and outdoor installations where connectors and cables are subject to frequent motion or environmental stress.

Cable Strain Relief

Performance Parameters

The performance parameters of an electronic connector provide critical data for evaluating suitability under operational and environmental conditions. These include:

  • Current rating – The maximum continuous current (in amperes) a connector can safely carry without overheating.
  • Voltage rating – The highest voltage a connector can withstand without insulation breakdown.
  • Operating temperature range – The environmental temperature limits for safe operation, important for military and automotive connector selection.
  • Contact resistance – The electrical resistance at the interface between connector contacts, impacting signal quality.
  • Insulation resistance – The degree to which a connector prevents unwanted current leakage.
  • Environmental sealing – Protection against dust, moisture, and contaminants (often referenced with IP or NEMA ratings).
  • Mating force – The insertion/extraction force required to mate and unmated the connector.

Evaluating these specifications allows engineers and buyers to choose ruggedized connectors for harsh environments or high-reliability connectors for mission-critical systems.

Features of Electronic Connectors

Some electronic connectors offer specialized features tailored for demanding environments or applications, which include:

  • Hermetically Sealed Connectors feature a glass-to-metal or ceramic-to-metal seal for airtight and watertight protection. These connectors maintain electrical integrity in extreme temperatures, high pressure, and corrosive environments, making them ideal for aerospace, military, and submersible equipment.
  • Water Resistant Connectors safeguard electronic circuits from water ingress due to splashes or temporary exposure. However, they are not intended for continuous submersion, typically found in consumer electronics and industrial machinery.
  • Moisture and Oil Resistant Connectors offer durable protection against harsh environments where contact with oil, grease, or humidity is common, such as manufacturing plants or automotive assemblies.
  • EMI and RFI Filtering Connectors integrate electromagnetic interference (EMI) and radio frequency interference (RFI) filtering to ensure signal quality and system reliability, crucial for medical electronics, industrial automation, and high-speed data systems.
  • ESD Shielded Connectors include electrostatic discharge (ESD) protection measures to prevent ESD-induced damage, which is essential for sensitive microelectronics, test instrumentation, and PCB connectors.

Additional advanced features may include polarization, quick-disconnect latches, alignment guides, and overmolded housings for further protection and ease of use. Selecting electronic connectors with suitable features ensures efficient performance, long-term reliability, and minimal maintenance in your application.

Leading Manufacturers and Suppliers

    Mouse Over Company Names to see their previews

    Chapter 3: Types of Electronic Connectors

    Electronic connectors are categorized based on the level of interconnection:

    • Integrated circuit (IC) chip level
    • IC-to-package level
    • IC package-to-board level
    • Board-to-board level
    • Wire-to-board or subassembly-to-subassembly level
    • Box-to-box level or connection between systems
    Levels of Electronic Interconnection

    Electronic Connector Types

    The world of electronics is ever growing and depends on electronic connectors to establish connections between various components. The use of electronic connectors has led to the development of a wide range of sizes, types, and distinctive electronic connectors that provide seamless connectivity.

    Board-to-Board Connectors

    Board-to-board connectors are a group of connectors that join printed circuit boards (PCB) without using a cable. They consist of a plug and socket and are included PCBs by vias, which are through-hole, or surface mounts. The connections for PCBs can be perpendicular or parallel with mezzanine connector PCBs being a stacking configuration, while edge connectors mate on the edges of single-sided or double-sided PCBs.

    Mezzanine Connectors

    Edge Connectors

    Box Header Connectors

    Box header connectors or shrouded header connectors are a form of board-to-board connector that have exposed pins with a plastic guide box. The design of box header connectors makes mating easier. They come with keying to prevent mismating and can have a notch cut out of the box to ensure correct mating.

    Box Header

    Pin Header

    Backplane Connectors

    A backplane functions as a central framework that interconnects multiple PCBs, aligning the pins of one board with corresponding pins on other boards. They are commonly used in computers and telecommunications equipment for data exchange between components. The name for backplane connectors comes from their use with mainframe computers where they were located at the back of the mainframe’s casing. In modern computers, they are part of top of rack switch applications and hybrid hard drive (HHD) clusters.

    Backplane

    Power Connectors

    Power connectors are connectors that allow electrical current to pass through them to provide power to a device. They carry either a direct current (DC) or an alternating current (AC).

    Barrel Connectors

    Barrel connectors, also known as coaxial power connectors, connect electronic devices to an external power source. Low voltage DC from a wall-mounted adaptor is transmitted to the electronic device through a barrel connector. They are widely used in consumer electronics and are available in standard diameters and lengths.

    The barrel plug is composed of concentric metal cylinders separated by an insulating layer. The inner cylinder contains the pin of the barrel jack. The various methods for mounting the barrel jack are on a PCB, panel, or cable. Inside the jack, a cantilevered spring presses against the outer sleeve of the plug, ensuring that the inner sleeve makes contact with the pin.

    Barrel Connector

    Molex Connectors

    Invented and patented by the Molex Connector Company in the late 1950s, Molex connectors are used for powering computer drives and other devices. Molex connectors consist of cylindrical spring metal pins that connect with matching cylindrical spring metal sockets. With keyed configurations for correct alignment, Molex connectors can have between 2 and 24 contacts with pins and sockets secured in a plastic housing.

    Molex Connector

    IEC Connectors

    IEC connectors are connectors that meet the standards stipulated in IEC 60320. The content of IEC standard 60320 specifies the components for connecting power supply cords to electrical equipment with a voltage rating of 250 V and a current rating of 16 A. IEC connectors vary in accordance with their current rating, temperature rating, dimensions, and number of terminals.

    The components of IEC connectors include an outlet power end or male component and an inlet female component. IEC components are identified by the prefix “C” followed by a number with the number of the inlet or female being one higher than that of the outlet or male component. The C13 connector is matched with the C14 inlet, which have three conductors, a current rating of 10 A, and a maximum temperature rating of 700°C.

    IEC Connector

    NEMA Connectors

    A NEMA connector is a category of power plugs and female receptacles that are compliant with the standards of the National Electrical Manufacturers Association (NEMA). Although NEMA standards are common in North America, they are also used internationally by a few countries.

    The distinguishing feature of NEMA connectors is the coding system that uses a set of numbers and letters to describe a connector’s characteristics. The initial code identifies the locking mechanism. Connectors beginning with the letter “L” have a twist-lock feature. If there’s no letter, it is a non-locking connector. The second part of the code, a number before the hyphen, specifies the NEMA type, which denotes the number of poles or current-carrying terminals, wire connections, voltage rating, and other identifying features. The number after the hyphen is a connector’s current rating in amperes. The final letter of the code is a “P” for plug and “R” for female receptacle.

    Non-locking NEMA connectors have straight blades on their plugs, making them easy to connect and disconnect from their female receptacles. In contrast, twist-locking NEMA connectors use curved blades that can be rotated and locked into place, preventing accidental disconnection. Twist-locking connectors are suited for industrial and commercial settings where secure tight connections are a necessity.

    NEMA 1-15P

    Radio Frequency (RF) Connectors

    RF connectors are designed to work with radio frequencies in the multi-megahertz range. They maintain shielding for coaxial cables, which has earned RF connectors the name of RF coaxial connectors. RF connectors help establish electrical connections for radio frequency transmission systems. The structure of a RF connector includes a center conductor, outer conductor, and insulation to maintain shielding for the coaxial cable.

    As with many connectors, RF connectors have female and male versions. In many instances, RF connectors are used for applications unrelated to radio frequencies due to their protective shielding. Fastening and spring mechanisms are included with RF connectors to reduce insertion forces.

    Radio Frequency Connectors

    Terminal Blocks

    A terminal block is a modular, insulated device designed to connect or terminate multiple wires. It has a series of terminals aligned in a strip with each terminal linked to a metal strip inside the block. The metal strip allows for electrical conduction between the connected terminals, while a clamping mechanism holds the wires in place. Terminal blocks can be oriented horizontally, vertically, or at a 45-degree angle, and can be mounted on panels or DIN rails.

    Terminal blocks are categorized based on:

    1. Their Structure

      • Single feed terminal blocks are used in wire-to-wire connections. They have one input and one output contact.
      • Multiple level terminal blocks have two or more levels of connection terminals. They reduce space and simplify wiring. DIN rail terminal block is an example of a multiple-level terminal block that is commonly found in power cabinets.
    2. Their Application

      • Ground Terminal Blocks
      • Fused Connection Terminals
      • Thermocouple Terminal Blocks
      • I/O Blocks and Sensor Blocks
      • Disconnect Terminal Blocks
      • Power Distribution Terminal Blocks
      • PCB Terminal Blocks
    3. Their Clamping System

    Screw Terminal Blocks

    Screw terminal blocks press the wire and the strip together and are the most common type of terminal block due to their ability to accommodate a wide range of wire sizes. A ferrule, Latin for small bracelet, is a metal tube that is placed over stranded wire to secure the strands for a screw terminal. They are narrow metal circular rings that reinforce, secure, and bind together strands.

    Screw Terminal Block

    Spring-Clamp Terminal Blocks

    Spring-clamp terminal blocks are suitable for clamping smaller wires and are used to attach wires to the strip. The three forms of terminal blocks are single pass through, dual level, and three level. Spring-clamp terminal blocks are capable of handling multiple wires due to their very secure clamping mechanism.

    Spring-Clamp Terminal Block

    Push-In Terminal Blocks

    Push-in terminal blocks or quick disconnect terminal blocks can be male or female. Male push-in terminal blocks include tabs that provide connection with female terminals. The female version has holes to accept male tabs. There are several types of push-in terminal blocks making it possible to adjust them to fit any application.

    Push-In Terminal Block

    Barrier Terminal Blocks

    Barrier terminal blocks have a plastic or metal housing that make it possible to connect several wires or conductors to a circuit. The design of barrier terminal blocks includes a pressure plate or set of screws for clamping wires in place. Barrier terminal blocks are widely used for their versatility and ability to be installed, dismantled, and reconnected.

    Barrier Terminal Block

    Universal Serial Bus (USB) Connectors

    A USB is an interface used for data transfer and power supply. They are found in smartphones, computers, and consumer electronics. USB connectors have a male component that plugs into a female port and have four or more shielded contacts enclosed in a plastic housing with a molded strain relief. Except for USB-C, USB connectors have an asymmetrical design that serves as a keying mechanism to ensure proper alignment.

    The versions of USBs include USB 1.0, USB 1.1, USB 2.0, USB 3.0, USB 3.1, and USB 3.2. Newer versions offer faster data transfer speeds but are backward compatible with older versions.

    USB connectors are categorized by their receptacles and sizes. USB-A and USB-B have male and female versions while USB Minis are divided into Mini-A, Mini-B, and Mini-AB. USB Micros are compartmentalized into Micro-A, Micro-B, and Micro-AB with USB-C being a version onto itself.

    USB-A female connectors are commonly used as host ports in computers, hubs, or devices. They allow for peripherals to be connected. USB-A female extension cables have a female A connector on one end and a male A connector on the other end.

    USB-A male connectors are found in keyboards and mice attached to built-in cables. They are used on USB memory sticks and designed for board mounting.

    USB-B female connectors are larger. They are used in applications where size is less critical. USB-B female connectors are known for their reliability and are used in removable and via or through-hole board mount applications.

    USB-B male connectors are at the end of cables. Their affordability is the reason for their widespread use.

    USB Mini female connectors were used on older MP3 players, cell phones, and external hard drives as surface mount connectors. They have been replaced by USB Micro connectors.

    USB Micro connectors are smaller than their predecessors and include a fifth pin for low-speed signaling, making them suitable for USB-OTG (On-The-Go) applications.

    USB Connector

    Audio and Video Connectors Types

    Audio and video connectors are a diverse category of electronic connectors designed to transmit audio and video signals. They can handle analog and digital signals using male (plug) components and female (jack) components.

    Audio connectors support monophonic (single audio channel) or stereophonic (multiple audio channels) signal systems.

    Types of audio and video connectors include:

    Phone Connectors have coaxial contacts that include a tip (T), ring (R), and sleeve (S). They are used in combination with 3 to 5 contacts and are found in phones, headphones, speakers, and other audio devices.

    Phone Connector

    DIN Connectors were originally standardized by the Deutsches Institut für Normung (DIN) and are used for transmitting analog audio signals. They have three or more metal pins arranged in a conductive ring and include a notch in both the male and female components to ensure proper alignment. Mini-DIN connectors are smaller versions of standard DIN connectors.

    DIN Connector

    RCA Connectors are used for transmitting stereo audio and video signals with an outer conductor and central pin as an inner conductor. They are color-coded with yellow for composite video and red and white for audio stereo.

    RCA Connectors

    XLR Connectors are circular connectors with three to seven pins and a notch that acts as a keying mechanism to ensure proper connection. They are commonly used for professional audio and video applications. The XLR stands for “External Line Return”. The balanced wiring of XLR connectors cancels out interference and enables XLR connectors to carry 48 V phantom power.

    High-Definition Multimedia Interface (HDMI) Connectors are used in modern home entertainment devices, projectors, computer monitors, and digital audio devices. HDMI connectors help transition minimized differential signaling (TMDS) technology to large amounts of digital data. Standard types of HDMI connectors include the standard (type A), dual-link (type B), mini (type C), micro (type D), and Automotive Connection System (type E) HDMI connectors.

    HDMI Connector

    DisplayPort (DP) Connectors link audio and video sources to displays, like monitors, TVs or projectors, are used for high-definition graphic displays, and computer systems. DisplayPort connectors are available in different versions, which are designed to transmit video and audio signals through a single cable. They have 20 or more pins and come in varying lengths.

    Displayport Connector

    Digital Visual Interface (DVI) Connectors are able to support analog and digital video signals over a single cable. Unlike HDMI connectors, DVI connectors can only transmit video signals. They were introduced as a replacement for VGA connectors and have become one of the most commonly used video connectors. DVI connectors are important for computers due to their ability to transmit video signals over long distances.

    VGA Connectors

    Video Graphic Array (VGA) Connectors are a standard interface for connecting video generating devices to display screens. They have 15 pins arranged in three rows inside a trapezoidal housing and were designed to carry analog video signals. VGA connectors were developed by IBM in 1987 for displaying video from computers. They have been replaced by DVI and HDMI cables. VGA connectors are used on old equipment and certain special applications.

    Chapter 4: Electronic Connector Mounting and Terminations

    There are several choices when it comes to connector mounting, which is how leads of the connector mount or fasten to a circuit board. The different types of mountings include surface mounting (SM), through the hold, hanging, cutout, and through the board. Although the terms termination and mounting are used interchangeably, there are distinct differences between them.

    The term mounting refers to the overall project and how the connectors interface, fasten, and attach. Termination refers to how the connection is being made and may indicate how the connector is attached at either end.

    Mounting Types

    The term mount can be confusing in regard to what it is referring to. In general, mount or mounting is an all encompassing term that describes how connectors are attached. The many varieties of connectors require different types of mounting methods, which vary according to the terminating leads and type of connector.

    • Pin Through Hole - Pin through hole mountings are used when terminating leads are attached to a circuit board through holes or vias placed in a board.

      Through-Hole Mount

    • Surface Mounting - Surface mounting attaches terminating leads using contact pads on the board.
    • Panel Mounting - Panel mounting is a surface mounting where the connector is placed against a hole with connecting variations being threading or a nut to hold the connector in place.
    • Hanging - With a hanging mounting, the connector is installed on the cable to which it is terminated.
    • Cutout Mounting - Cutout mounting involves placing the connector at the edge of the board to take advantage of the edge placement. To provide for the mounting, the board has been cutout such that the connector can have a lower profile. The use of cutout mounting is due to the fact that there is no other space for placement.
    • Through the Board Mounting - Through the board mounting is a combination of cutout mounting and panel mounting. Terminations mount through the board using holes in the board and solder on the same side as the connector’s mates as others are surface mounted to the side of the board the connectors mount from.

    Termination Methods

    Termination methods vary depending on personal preference with some terminations requiring a specific type. The determining factors are the needs of an application and the stipulations of a project.

    Through Hole Soldering

    In board-to-board and wire-to-board connections, solder terminations are used on through-hole mount or surface mount devices. In through-hole terminations, the terminals are inserted into drilled holes and soldered on the contact pads located on the other side of the board.

    Surface Mount Termination

    With surface mount terminations, the leads and mounting pads are on the same side of the board. Components are placed by hand and soldered using reflow or wave soldering. Terminals are soldered on contact pads on the same side as the connector.

    Crimping

    Crimp connections involve compressing electrical wires and cables against a crimp termination or splice band. The compression reshapes the wire strands to create a low-resistance electrical connection, akin to a cold weld.

    Crimping is crucial for reliable terminal connections. Improper crimping can result in electrical failures or even fires. Ensuring correct wire preparation, sizing, and using appropriate termination types, tools, and settings are vital for dependable and permanent connections. The crimping process starts with evaluating and measuring the wire's cross-section.

    The crimping tool is either a ratchet or manual crimper. The jaws of the crimper cover the entire surface area of the connector and are equipped with crimping dies designed to match the gauge of the wire. Dies are color coded to indicate correct placement of the wire.

    The wire to be crimped fits in the barrel of the connector, which is typically 0.25 inches (0.64 cm) in diameter. Once placed, the jaws of the crimper close and apply pressure to the barrel and wire. The compression removes the insulation from the wire exposing the conductors.

    A strong connection between the connector and wire is critical for preventing connection failure and collateral damage. A final step in the crimping process involves twisting and tightening the exposed wire to ensure a secure fit.

    The stripped exposed wire is inserted into the barrel of the connector until the insulation of the wire touches the barrel. None of the exposed wire should be visible at the entrance of the barrel or past the barrel into the tongue of the terminal.

    The connector and stripped wire are placed back in the crimper die in a horizontal position with the barrel side facing upward and the flat side downward. The color of the die on the crimper should match the color of the insulation wire. The slot or die must match the gauge of the wire.

    The crimper is placed perpendicular to the connector and stripped wire such that the crimper can firmly hold them. The jaws of the crimper should be placed closer to the tongue of the connector than to the insulation of the wire. Once positioned, the jaws of the crimper are closed with great force such that the wire cannot be removed when it is pulled away from the terminal.

    Electrical tape or a heat shrink seal are used to protect the wire and connector of the terminal against exposure to the elements. The adhesive of the electrical tape makes a tight connection while heat shrinking involves applying heat melts plastic material and causes it to deform to the shape of the terminal.

    Crimping eliminates the need for soldering wire connections and avoids potential failure associated with soldered joints that become brittle and crack. Terminal manufacturers supply information regarding the appropriate tooling and materials for completing a connection that should be followed to prevent wiring failures.

    Ratchet crimp tools provide tactile evidence that the terminal crimp has been fully compressed and have color coding for easy identification of the proper die. Additionally, the jaws of a ratchet crimp tool will not open until the crimp between the connector and wire is sufficiently snug and tight.

    Crimping

    Insulation Displacement Connectors

    Insulation Displacement Connectors (IDCs) have sharp blades that strip the wire insulation as the wire or cable is inserted. Once properly placed, the exposed area of the wire is cold-welded to the connector terminal, creating a secure and reliable connection. The insulation displacement is commonly used on ribbon cable connectors and telephone and network plugs.

    Insulation Displacement Connector

    Push-In Termination

    Push-in terminations are reliable and rugged terminations that can be temporary or permanent. Wires are stripped and pushed into the connector or locked in. Although the push-in and locked in methods are most common, there are several variations of push-in terminations. They are quite common and used with several types of connectors. Push-in terminations are restricted to applications that do not have any vibrations that could break or loosen the connection. A vibration rating of an application is required for the use of push-in terminations.

    Conclusion

    • Electronic connectors are devices that join electronic circuits. They are used for installing, assembling, and supplying power to electrical devices.
    • The two main components of electronic connectors are the housing and the terminals.
    • Electronic connectors have a male (plug) and a female (jack or socket) components.
    • Keying and locking mechanisms are important features of connectors that ensure correct and secure connections. A strain relief protects the connector assembly from mechanical stress.
    • The number of contacts refers to the number of conductive elements that make an electrical connection. The contact pitch refers to the center-to-center distance of adjacent contacts or pins.
    • Mounting refers to the placement of electronic connectors in the electrical devices.
    • Termination refers to the method of fastening terminals. The types of termination methods are soldering, crimping, and insulation displacement.
    • Electronic connectors can be classified based on their level of interconnection.

    Leading Manufacturers and Suppliers

      Mouse Over Company Names to see their previews

      Table of Contents

      What are Electronic Connectors?

      Terminologies Used in Electronic Connectors

      Types of Electronic Connectors

      Electronic Connector Termination

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