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iv The electronic connector book

Table of Contents

Preface.....................................................................19

Part A - Concepts.....................................................22

Chapter 1 Introduction..............................................1

1.1 Chapter introduction........................................1

1.1.1 Tidbits.........................................................................1

1.2 Book orientation..............................................1

1.2.1 Interconnect definition...............................................1

1.2.2 Book parts...................................................................1

1.2.3 How to use this book..................................................2

1.2.4 Beyond this book........................................................2

1.3 History.............................................................2

1.3.1 Milestones..................................................................3

1.3.1.1 The pioneers - 1870s to 1920s.....................................................3

1.3.1.2 The innovators - 1930s to 1950s..................................................4

1.3.1.3 The optimizers - 1960s to today...................................................5

1.3.1.4 The future.....................................................................................5

1.3.2 Evolution timeline......................................................5

1.4 FAQ..................................................................6

1.4.1 Why so many damn connectors?................................7

1.4.2 Can you help me make a computer cable?.................7

1.4.3 How do I repair this connector?.................................7

1.4.4 What is the weirdest connector you have seen?.........7

1.4.5 What is the funniest connector you have seen?..........8

1.5 Interconnect classification...............................8

1.5.1 Manufacturer, vendor, end user classification............8

1.5.2 Drawing from Linnaean taxonomy............................9

1.5.3 Classes of interconnects...........................................10

Chapter 2 Interconnect characterization..................13

2.1 Chapter introduction......................................13

2.1.1 Tidbits.......................................................................13

2.1.2 International glossary...............................................13

2.1.3 Chapter orientation...................................................18

2.2 Terminology...................................................21

2.2.1 Misused or misunderstood terms..............................22

2.2.1.1 Male, female, hermaphrodite, genderless..................................22

2.2.1.2 Hermaphrodite, genderless, self-mating....................................22

2.2.1.3 Plugs and jacks...........................................................................23

2.2.1.4 Socket.........................................................................................25

2.2.1.5 Receptacle..................................................................................25

2.2.1.6 Wire, cable, harness, cord, cable assembly................................26

2.2.1.7 Ribbon cable, FFC, FPC............................................................26

2.2.1.8 Port vs. connector.......................................................................27

2.2.2 Poorly defined and missing terms............................28

2.2.2.1 Inconsistently used terms...........................................................28

2.2.2.2 Misappropriated names..............................................................28

2.2.2.3 Missing terms.............................................................................28

2.3 Main attributes...............................................29

2.3.1 Access.......................................................................29

2.3.1.1 Exterior interconnects................................................................29

2.3.1.2 Interior interconnects.................................................................29

2.3.2 Interconnect structure...............................................30

2.3.2.1 Removable and permanent termination.....................................30

2.3.2.2 Separable and inseparable connection.......................................30

2.3.2.3 Mating in family and out of family............................................30

2.3.2.4 Interconnect structure list...........................................................30

2.3.2.5 Inseparable, non-electric............................................................31

2.3.2.6 Inseparable, permanent..............................................................31

2.3.2.7 Inseparable, removable..............................................................32

2.3.2.8 Single mating face not in family................................................32

2.3.2.9 Two mating faces not in family..................................................33

2.3.2.10 Single mating interface in family.............................................33

2.3.2.11 Two mating interfaces in family..............................................33

2.3.3 Interconnection topology..........................................34

2.3.3.1 To-wire/cable topologies............................................................35

2.3.3.2 Wire/cable-to-board topologies..................................................36

2.3.3.3 Board-to-board topology............................................................37

2.3.3.4 To-panel topologies....................................................................38

2.3.3.5 To-device topologies..................................................................38

2.3.3.6 Multiple interconnection topologies..........................................38

2.3.4 Number of circuits....................................................39

2.3.5 Permutations of main characteristics........................40

2.3.5.1 Permutations for interior interconnects......................................41

2.3.5.2 Permutations for exterior interconnects.....................................42

2.4 Termination, mount, and mating....................42

2.4.1 Termination...............................................................43

2.4.1.1 Termination definition................................................................43

2.4.1.2 Termination examples................................................................43

2.4.2 Mount.......................................................................44

2.4.2.1 Mount definition........................................................................44

2.4.2.2 Mount examples.........................................................................44

2.4.2.3 Loose connectors.......................................................................45

2.4.2.4 In-line interconnects...................................................................45

2.4.2.5 Mounted interconnects...............................................................45

2.4.3 Mating......................................................................46

2.4.3.1 Mating definition.......................................................................46

2.4.3.2 Mating characteristics................................................................46

2.4.4 Termination, mount, and mating combinations........47

2.5 Wire/cable termination...................................47

2.5.1 Wire /cable specifications.........................................48

2.5.1.1 Wiring conductors......................................................................49

2.5.1.2 Wire specifications.....................................................................49

2.5.1.3 Aluminum and copper oxidation................................................49

2.5.1.4 Wire size color code...................................................................49

2.5.1.5 Cable specifications...................................................................50

2.5.2 Wire entry orientation...............................................50

2.5.2.1 Single-ended orientation for wire terminals..............................50

2.5.2.2 End-to-end wire orientation for splices......................................50

2.5.2.3 Board-in wire orientations.........................................................51

2.5.2.4 Wire orientations for plugs.........................................................51

2.5.2.5 Orientations for panel-mount receptacles..................................53

2.5.2.6 Cable-to-cable orientations........................................................53

2.5.2.7 Cable-to-panel orientations........................................................54

2.5.2.8 Wire-to-board orientations.........................................................54

2.5.3 Permanent unstripped wire/cable termination..........55

2.5.3.1 Insulation displacement wire termination..................................55

2.5.3.2 FFC termination.........................................................................56

2.5.3.3 Ribbon cable mass termination..................................................57

2.5.4 Permanent stripped wire/cable termination..............57

2.5.4.1 Fixed vs. insertable contacts......................................................57

2.5.4.2 Contact extraction direction.......................................................58

2.5.4.3 Wire crimping............................................................................59

2.5.4.4 Terminal Position Assurance (TPA)...........................................59

2.5.4.5 Wire entry sealing......................................................................60

2.5.4.6 Permanent poke-in termination..................................................60

Table of Contents v

2.5.4.7 Soldering termination.................................................................60

2.5.4.8 Ultrasonic termination...............................................................60

2.5.4.9 Wire-wrap termination...............................................................61

2.5.4.10 Control cable termination........................................................61

2.5.4.11 Coaxial cable termination........................................................61

2.5.4.12 Permanent stripped ribbon cable term.....................................61

2.5.5 Removable wire/cable termination...........................61

2.5.5.1 Wire cage termination................................................................61

2.5.5.2 Twist termination.......................................................................62

2.5.5.3 Screw termination......................................................................63

2.5.5.4 Clamp termination.....................................................................63

2.5.5.5 Removable poke-in termination.................................................63

2.5.5.6 Removable ribbon cable termination.........................................63

2.5.6 Wire termination arrangement..................................63

2.5.6.1 Wire termination pattern............................................................63

2.5.6.2 Termination points per circuit....................................................63

2.5.6.3 Termination pitch.......................................................................64

2.5.6.4 Termination rows.......................................................................64

2.6 PCB mount and termination..........................64

2.6.1 PCB termination technology....................................64

2.6.1.1 Through-hole mount..................................................................65

2.6.1.2 Surface-mount............................................................................65

2.6.1.3 Surface and through-hole mount................................................65

2.6.1.4 Press-fit mount...........................................................................66

2.6.2 PCB terminal arrangement.......................................66

2.6.2.1 PCB terminal pattern..................................................................66

2.6.2.2 PCB terminal pitch.....................................................................67

2.6.2.3 PCB terminal rows.....................................................................67

2.6.3 PCB mount orientation.............................................67

2.6.3.1 Straight connectors.....................................................................68

2.6.3.2 Bottom entry connectors............................................................68

2.6.3.3 Through-board connectors.........................................................68

2.6.3.4 Over-board connectors...............................................................69

2.6.3.5 Right-angle connectors..............................................................69

2.6.3.6 Under-board connectors.............................................................69

2.6.3.7 Straddle-mount connectors........................................................70

2.6.3.8 End-launch connectors...............................................................70

2.6.3.9 Cutout-mount connectors...........................................................71

2.6.3.10 Angled connectors....................................................................71

2.7 Other mounts and terminations......................72

2.7.1 Panel mount..............................................................72

2.7.1.1 Flush panel mount......................................................................72

2.7.1.2 Through-panel mount.................................................................72

2.7.1.3 Panel mount grounding, isolation..............................................73

2.7.1.4 Panel-mount orientation.............................................................73

2.7.1.5 Panel-mount second termination................................................74

2.7.1.6 Panel sealing..............................................................................74

2.7.2 Board, rail, stud, bus bar, and foil............................74

2.8 Housing..........................................................75

2.8.1 Connector assembly parts.........................................75

2.8.2 Housing materials.....................................................75

2.8.2.1 Insulation housing......................................................................75

2.8.2.2 Metal shells and latches.............................................................76

2.8.2.3 Gaskets and seals.......................................................................76

2.8.3 Housing color...........................................................76

2.8.4 Plug cable entry........................................................77

2.8.4.1 Cable entry support, retention....................................................77

2.8.4.2 Cable sealing..............................................................................77

2.8.4.3 Cable shielding...........................................................................77

2.8.5 Multiple parts connectors.........................................77

2.8.5.1 Vertically stackable connectors..................................................78

2.8.5.2 End-stackable connectors...........................................................78

2.8.5.3 Interlocking connectors..............................................................78

2.8.5.4 Configurable connectors............................................................78

2.8.6 Integrated components connectors...........................79

2.8.6.1 Filtered connectors.....................................................................79

2.8.6.2 Integrated magnetics connectors................................................79

2.8.6.3 LED status connectors...............................................................79

2.8.6.4 Integrated transducer fiber optic connector...............................80

2.9 Contacts.........................................................80

2.9.1 Contact gender..........................................................80

2.9.1.1 Contact gender definition...........................................................80

2.9.1.2 Contact gender match................................................................81

2.9.1.3 Male contacts.............................................................................82

2.9.1.4 Female contacts..........................................................................82

2.9.1.5 Hermaphrodite contacts.............................................................83

2.9.1.6 Genderless contacts....................................................................83

2.9.2 Contact characteristics..............................................84

2.9.2.1 Contact sizes..............................................................................84

2.9.2.2 Contact manufacturing process..................................................85

2.9.2.3 Contact materials.......................................................................85

2.9.2.4 Contact point and contact wipe..................................................87

2.9.2.5 Contact fretting..........................................................................87

2.9.2.6 Contact lubrication.....................................................................88

2.9.2.7 Antispark tip...............................................................................88

2.9.2.8 Contact pressure.........................................................................88

2.9.3 Special contact functions..........................................88

2.9.3.1 Differential pair contacts............................................................89

2.9.3.2 Shield contacts...........................................................................89

2.9.3.3 Power Earth contact...................................................................89

2.9.3.4 ZIF contacts...............................................................................89

2.10 Connector gender and arrangement.............89

2.10.1 Connector gender...................................................89

2.10.1.1 Four connector genders............................................................89

2.10.1.2 Gender-bending connectors.....................................................90

2.10.1.3 Why care about connector gender?..........................................91

2.10.1.4 Tongue and groove...................................................................91

2.10.2 Contact arrangement...............................................91

2.10.2.1 Contact pattern.........................................................................91

2.10.2.2 Position numbering..................................................................92

2.10.2.3 Mating pitch.............................................................................92

2.10.2.4 Row spacing.............................................................................93

2.10.2.5 Blade orientation......................................................................93

2.10.2.6 Hybrid connectors....................................................................93

2.10.2.7 Mating, termination, PCB arrangements.................................94

2.11 Mating face..................................................95

2.11.1 Mating face shape and size.....................................95

2.11.1.1 Mating face shape....................................................................95

2.11.1.2 Mating width and diameter......................................................95

2.11.2 Mating face surface................................................95

2.11.2.1 Stepped face.............................................................................96

2.11.2.2 Partitioned face........................................................................96

2.11.2.3 Face protrusions.......................................................................97

2.11.3 Shroud.....................................................................97

2.11.3.1 Shrouded and enshrouded mate...............................................97

2.11.3.2 Shroud types.............................................................................97

2.11.3.3 Shroudless................................................................................98

2.11.3.4 Partial shroud...........................................................................98

2.11.3.5 Full shroud...............................................................................99

2.11.3.6 Self-mating shroud...................................................................99

2.11.4 Mating face sealing.................................................99

2.11.4.1 Rectangular face sealing........................................................100

2.11.4.2 Round face sealing.................................................................100

2.12 Mates compatibility...................................100

2.12.1 Connector dimorphism.........................................101

2.12.1.1 Dimorphism in all connectors................................................101

2.12.1.2 Dimorphism determination....................................................102

2.12.2 Family polarity.....................................................103

2.12.2.1 Gendered family polarity.......................................................104

2.12.2.2 Reverse polarity.....................................................................104

2.12.2.3 Hermaphrodite family polarity..............................................106

2.12.2.4 Genderless family polarity.....................................................106

2.12.2.5 Plug, receptacle, and header gender.......................................106

2.12.3 Polarization, conforming, keying, coding............107

2.12.3.1 Polarization............................................................................107

2.12.3.2 Conforming............................................................................108

2.12.3.3 Keying....................................................................................111

2.12.3.4 Coding....................................................................................112

vi The electronic connector book

2.13 Mating........................................................113

2.13.1 Mating and unmating action.................................113

2.13.1.1 Mating direction.....................................................................113

2.13.1.2 Blind mating...........................................................................113

2.13.1.3 Connector misalignment........................................................114

2.13.1.4 Alignment features.................................................................114

2.13.1.5 Misalignment accommodation...............................................114

2.13.1.6 Mating, retention, and unmating forces.................................115

2.13.1.7 Mated height..........................................................................116

2.13.2 Multiple mating interfaces....................................116

2.13.2.1 Single-face connectors for multiple mates.............................116

2.13.2.2 Connectors with multiple mating faces..................................117

2.13.2.3 Connectors with two mating options.....................................118

2.14 Fastening....................................................118

2.14.1 Fastening introduction..........................................118

2.14.1.1 Fastening methods..................................................................118

2.14.1.2 Latched mate..........................................................................121

2.14.1.3 Latch location.........................................................................122

2.14.2 Unlatched..............................................................123

2.14.2.1 Compression..........................................................................123

2.14.2.2 Friction fastening...................................................................123

2.14.2.3 Snap-on fastening...................................................................123

2.14.2.4 Magnetic fastening.................................................................123

2.14.3 Self-latching.........................................................124

2.14.3.1 Self-latching contact..............................................................124

2.14.3.2 Ejector latching......................................................................124

2.14.3.3 Self-latching, lever release.....................................................124

2.14.3.4 Self-latching, slide release.....................................................125

2.14.3.5 Self-latching, twist ring release..............................................126

2.14.3.6 Self-latching, button release...................................................126

2.14.3.7 Inertia latching.......................................................................126

2.14.3.8 Connector position assurance (CPA).....................................127

2.14.4 Manual latching....................................................127

2.14.4.1 ZIF fastening..........................................................................127

2.14.4.2 Contact twist fastening...........................................................127

2.14.4.3 Threaded ring fastening.........................................................128

2.14.4.4 Screw fastening......................................................................128

2.14.4.5 Spring fastening.....................................................................128

2.14.4.6 Clip ring fastening..................................................................128

2.14.4.7 Lever fastening.......................................................................128

2.14.4.8 Buckle latch fastening............................................................128

2.14.5 Coupling...............................................................128

2.14.5.1 Bayonet coupling...................................................................128

2.14.5.2 Thread coupling.....................................................................129

2.14.5.3 Thread vs. bayonet comparison.............................................131

2.14.5.4 Cam coupling.........................................................................132

2.14.5.5 Screw coupling.......................................................................132

2.14.5.6 Spindle coupling....................................................................132

2.14.6 Locking.................................................................132

2.15 Ratings.......................................................132

2.15.1 Clarifications of ratings........................................132

2.15.1.1 Rating definition....................................................................132

2.15.1.2 Each rating is independent of others......................................133

2.15.1.3 Contacts carry current, not power..........................................133

2.15.1.4 Voltage × current is not contact power...................................133

2.15.2 DC characteristics for a single circuit..................133

2.15.2.1 Connection resistance............................................................133

2.15.2.2 Mating cycles.........................................................................134

2.15.2.3 Voltage drop and contact resistance.......................................134

2.15.2.4 Temperature rise.....................................................................135

2.15.2.5 Current rating and derating....................................................135

2.15.3 DC characteristics across circuits.........................135

2.15.3.1 Insulation resistance...............................................................136

2.15.3.2 Operating voltage...................................................................136

2.15.3.3 Dielectric withstand voltage..................................................136

2.15.4 AC characteristics.................................................137

2.15.4.1 dB...........................................................................................138

2.15.4.2 Characteristic impedance.......................................................138

2.15.4.3 Reflection coefficient, Return loss, VSWR...........................138

2.15.4.4 Insertion loss..........................................................................139

2.15.4.5 Cutoff frequency....................................................................139

2.15.4.6 Passive Intermodulation.........................................................139

2.15.4.7 Inter-capacitance and cross-talk.............................................139

2.15.4.8 High-speed characteristics.....................................................139

2.15.4.9 Shielding................................................................................140

2.15.5 Environmental......................................................140

2.15.5.1 Operating temperature...........................................................140

2.15.5.2 Altitude...................................................................................140

2.15.5.3 Harsh environments...............................................................140

2.15.5.4 IP rating..................................................................................140

2.15.5.5 Standard sealing.....................................................................141

2.15.5.6 Hermetic sealing....................................................................141

2.15.5.7 Firewall rating........................................................................141

2.16 Standards and application..........................141

2.16.1 Industry-standard, proprietary, and custom..........142

2.16.1.1 Industry-standard connectors.................................................142

2.16.1.2 Standards institutes and organizations...................................142

2.16.2 Regulatory certifications......................................142

2.16.2.1 Safety certifications...............................................................142

2.16.2.2 Performance certifications.....................................................143

2.16.2.3 Industry-specific certifications...............................................143

2.16.3 Application...........................................................143

2.17 Availability.................................................143

2.17.1 Region..................................................................144

2.17.2 Obsolescence........................................................144

Chapter 3 Identification and selection...................145

3.1 Chapter introduction....................................145

3.1.1 Tidbits.....................................................................145

3.1.2 Chapter orientation.................................................145

3.2 Identification process...................................145

3.2.1 Identification through Identiconn...........................145

3.2.1.1 Quick pick................................................................................146

3.2.1.2 Quick filter...............................................................................146

3.2.1.3 Navigate by type......................................................................147

3.2.1.4 Filter by characteristics............................................................148

3.2.1.5 Identiconn tips..........................................................................148

3.2.2 Identification through this book.............................149

3.2.2.1 Term search in this book..........................................................149

3.2.2.2 Picture search in this book.......................................................150

3.2.2.3 Flowchart search in this book..................................................152

3.2.3 Identification with online resources.......................153

3.2.3.1 Distributors’ websites...............................................................153

3.2.3.2 Search engines.........................................................................153

3.2.3.3 Picture search...........................................................................154

3.2.3.4 Ask the experts.........................................................................154

3.2.4 Buying an identified interconnect..........................154

3.3 Ways to select an interconnect.....................155

3.3.1 Select by asking the experts...................................155

3.3.2 Select through online tools.....................................155

3.3.2.1 Manufacturer and distributors sites..........................................155

3.3.2.2 Identiconn................................................................................156

3.3.3 Select by attributes in this book.............................156

3.4 Selection by main attributes.........................156

3.4.1 Main attribute solutions..........................................156

3.4.1.1 Selection by access..................................................................156

3.4.1.2 Selection by mating structure...................................................156

3.4.1.3 Selection by circuits.................................................................156

3.4.1.4 Selection by topology..............................................................157

3.4.2 Wire-to-wire solutions............................................157

3.4.2.1 Wire-to-wire, direct..................................................................157

3.4.2.2 Single wires, one-piece............................................................157

3.4.2.3 Single-wire connectors.............................................................159

3.4.2.4 Multi-wire connectors..............................................................160

Table of Contents vii

3.4.3 Cable-to-cable/wire solutions.................................161

3.4.3.1 Single-piece cable solutions.....................................................161

3.4.3.2 Control cable connectors..........................................................162

3.4.3.3 Connectors for other types of cable.........................................163

3.4.4 Wire-to-board solutions..........................................163

3.4.4.1 Direct wire-to-board.................................................................163

3.4.4.2 Single-piece wire-to-board.......................................................163

3.4.4.3 Two- piece wire-to-board.........................................................165

3.4.4.4 Wire-to-board connectors.........................................................165

3.4.5 Cable-to-board solutions........................................166

3.4.5.1 Direct-to-PCB cable-to-board soldering..................................166

3.4.5.2 Hot bar bonding, ACF, flex-on-board......................................166

3.4.5.3 Single-piece cable-to-board.....................................................167

3.4.5.4 Cable-to-board connectors.......................................................168

3.4.6 Board-to-board solutions........................................169

3.4.6.1 Parallel board-to-board solutions.............................................169

3.4.6.2 Perpendicular board-to-board solutions...................................175

3.4.6.3 Coplanar board-to-board solutions..........................................177

3.4.6.4 Orthogonal board-to-board solutions.......................................179

3.4.6.5 Tilted board-to-board solutions................................................180

3.4.7 Solutions for other connections..............................180

3.4.7.1 Wire-to-panel...........................................................................180

3.4.7.2 Board-to-panel.........................................................................180

3.4.7.3 Other conductors......................................................................180

3.5 Selection by secondary attributes................181

3.5.1 Interconnects that mate to devices..........................181

3.5.2 Selection by termination and mount.......................181

3.5.2.1 Wire termination......................................................................181

3.5.2.2 Cable termination.....................................................................182

3.5.2.3 PCB mount...............................................................................182

3.5.2.4 Panel mount.............................................................................183

3.5.3 Selection by features..............................................183

3.5.3.1 Housing features......................................................................183

3.5.3.2 Mating face features.................................................................183

3.5.3.3 Fastening features....................................................................184

3.6 Selection by application...............................184

3.6.1 Consumer products.................................................184

3.6.1.1 Home appliances......................................................................184

3.6.1.2 Audio and video, exterior.........................................................184

3.6.1.3 Power tool batteries..................................................................185

3.6.1.4 RC models................................................................................185

3.6.1.5 Small batteries..........................................................................186

3.6.1.6 AC adapters, chargers..............................................................186

3.6.1.7 Musical instruments.................................................................187

3.6.2 Solid-state lighting.................................................187

3.6.2.1 LED strips................................................................................187

3.6.2.2 LED panels...............................................................................188

3.6.2.3 LED lamps...............................................................................188

3.6.2.4 LED power supplies.................................................................188

3.6.2.5 Flat panel backlight connectors...............................................189

3.6.3 Computing devices.................................................189

3.6.3.1 Exterior connectors..................................................................189

3.6.3.2 Interior connectors, desktop computer.....................................189

3.6.3.3 Interior connectors, laptop computer.......................................190

3.6.3.4 Interior connectors, tablet computer........................................190

3.6.4 Vehicles, transportation..........................................191

3.6.4.1 Small EVs................................................................................191

3.6.4.2 Passenger vehicles...................................................................191

3.6.4.3 Other land vehicles..................................................................191

3.6.4.4 Marine vessels..........................................................................192

3.6.4.5 Aviation....................................................................................192

3.6.5 Premises wiring......................................................192

3.6.5.1 Utility-level power wiring........................................................192

3.6.5.2 Residential AC power wiring...................................................192

3.6.5.3 High-current DC wiring...........................................................193

3.6.5.4 Solar power..............................................................................193

3.6.5.5 Low-current DC wiring............................................................193

3.6.5.6 Telephone land line..................................................................194

3.6.6 Professional applications........................................194

3.6.6.1 Industrial..................................................................................194

3.6.6.2 Card cages, module crates, and racks......................................195

3.6.6.3 Stage, public address, and broadcast........................................199

3.6.6.4 Test equipment and fixtures.....................................................199

3.6.6.5 Information Technology...........................................................199

3.6.6.6 Telecom base station................................................................199

3.6.6.7 Extraction industry...................................................................199

3.6.6.8 Wearable radios........................................................................200

3.6.6.9 Security cameras......................................................................200

3.6.6.10 Medical..................................................................................200

3.6.7 Environment...........................................................200

3.6.7.1 Electromagnetic radiation........................................................200

3.6.7.2 Harsh environment, water........................................................201

3.6.7.3 Vibration..................................................................................201

3.6.7.4 Salt water spray........................................................................201

3.6.7.5 Immersion................................................................................201

3.6.7.6 Vacuum....................................................................................202

3.6.7.7 Mud and dirt.............................................................................202

3.6.7.8 Direct burial.............................................................................203

3.6.7.9 Nuclear radiation......................................................................203

3.6.7.10 Explosive, fire........................................................................203

3.6.8 High voltage, current, speed...................................203

3.6.8.1 High voltage rating..................................................................203

3.6.8.2 High-speed operation...............................................................203

3.6.8.3 High current rating...................................................................203

Part B - Catalog.....................................................206

Chapter 4 Test interconnects.................................207

4.1 Chapter introduction....................................207

4.1.1 Tidbits.....................................................................207

4.1.2 History of test interconnects...................................207

4.1.3 International glossary.............................................208

4.1.4 Selection, identification, and related classes..........209

4.1.4.1 Test interconnects selection.....................................................209

4.1.4.2 Test interconnect identification................................................209

4.1.4.3 Other classes related to test interconnects...............................210

4.1.5 Chapter orientation.................................................210

4.2 Technical notes, test interconnects...............210

4.2.1 Insulation piercing..................................................210

4.3 Handheld probes..........................................211

4.3.1 Meter probes...........................................................211

4.3.1.1 Meter probe tips.......................................................................211

4.3.1.2 Meter probe accessories...........................................................211

4.3.2 Scope probe tips.....................................................212

4.4 Test clips......................................................212

4.4.1 Alligators, crocodiles, clamps................................212

4.4.1.1 Crocodile clip...........................................................................213

4.4.1.2 Alligator clip............................................................................213

4.4.1.3 Piercing crocodile clip.............................................................213

4.4.1.4 Five-way alligator clip.............................................................213

4.4.1.5 Test clamp................................................................................214

4.4.2 Grabber clips..........................................................214

4.4.3 Test fixture grabbers...............................................215

4.4.3.1 Hook test fixture grabbers........................................................215

4.4.3.2 Piercing test fixture grabbers...................................................215

4.4.4 IC clips...................................................................216

Chapter 5 Terminals..............................................217

5.1 Chapter introduction....................................217

5.1.1 Tidbits.....................................................................217

5.1.2 History of terminals................................................217

5.1.3 International glossary.............................................218

5.1.4 Selection, identification, and related classes..........219

viii The electronic connector book

5.1.4.1 Terminal selection....................................................................219

5.1.4.2 Terminal identification.............................................................220

5.1.4.3 Classes related to terminals......................................................220

5.1.5 Chapter orientation.................................................220

5.2 Wire terminals..............................................221

5.2.1 Tongue crimp terminals..........................................221

5.2.1.1 Ring terminals..........................................................................222

5.2.1.2 Slotted ring terminals...............................................................222

5.2.1.3 Hook terminals.........................................................................223

5.2.1.4 Fork terminals..........................................................................223

5.2.1.5 Blade tongue terminals............................................................223

5.2.1.6 Knife tongue terminals.............................................................223

5.2.2 Wire terminals for wire cages.................................223

5.2.2.1 Advantages of termination for wire cages...............................223

5.2.2.2 Wire ferrules.............................................................................224

5.2.2.3 Wire pin terminals....................................................................225

5.2.2.4 Speaker pins.............................................................................225

5.2.3 Misc. wire terminals...............................................225

5.2.3.1 Wire socket terminals...............................................................225

5.2.3.2 Grounding wire terminals........................................................225

5.3 Board terminals............................................225

5.3.1 Board screw/threaded terminals.............................226

5.3.1.1 Swaged screw terminals...........................................................226

5.3.1.2 Through-hole screw terminals.................................................226

5.3.1.3 SMD threaded terminals..........................................................226

5.3.1.4 Press-fit threaded terminals......................................................226

5.3.1.5 Wire-cage PCB terminals.........................................................226

5.3.1.6 Broaching PCB fasteners.........................................................227

5.3.2 Board pins and posts...............................................227

5.3.2.1 Pins and posts...........................................................................227

5.3.2.2 Turrets......................................................................................228

5.3.2.3 Test points................................................................................229

5.3.3 Board sockets.........................................................229

5.3.3.1 Machined socket terminals......................................................229

5.3.3.2 Formed socket terminals..........................................................229

5.4 Other mount terminals.................................229

5.4.1 Loose terminals......................................................230

5.4.2 Panel mount terminals............................................230

5.4.2.1 Solder lugs...............................................................................230

5.4.3 Conductor-mount terminals....................................231

5.4.3.1 Magnet wire terminals.............................................................231

5.4.3.2 Foil terminals...........................................................................231

5.4.3.3 Bus bar clips.............................................................................232

Chapter 6 Wire splices..........................................233

6.1 Chapter introduction....................................233

6.1.1 Tidbits.....................................................................233

6.1.2 History of wire splices............................................233

6.1.3 International glossary.............................................234

6.1.4 Selection, identification, and related classes..........234

6.1.4.1 Wire splice selection................................................................234

6.1.4.2 Wire splice identification.........................................................235

6.1.4.3 Classes related to wire splices..................................................235

6.1.5 Chapter orientation.................................................235

6.2 Technical notes, wire splices.......................236

6.2.1 Wire splice types....................................................236

6.2.1.1 Permanent vs removable splices..............................................236

6.2.1.2 Joint vs. tap splices..................................................................236

6.2.1.3 Aluminum and copper..............................................................236

6.2.1.4 Splice kits.................................................................................237

6.2.2 Wire splice characteristics......................................237

6.2.2.1 Number of wire entries, wires per entry..................................237

6.2.2.2 Number of circuits...................................................................237

6.2.2.3 Wire direction...........................................................................237

6.3 Catalog of splices.........................................238

6.3.1 Insulation displacement splices..............................238

6.3.1.1 Button IDT splices...................................................................238

6.3.1.2 Side-by-side IDT splices..........................................................238

6.3.1.3 Hinged-cap IDT splices...........................................................239

6.3.2 Crimp splices..........................................................239

6.3.2.1 Butt crimp splices....................................................................239

6.3.2.2 Parallel splices, crimp sleeves..................................................240

6.3.2.3 Crimp band splices...................................................................240

6.3.2.4 Cap crimp splices.....................................................................240

6.3.2.5 B-wire piercing splices............................................................240

6.3.2.6 Multi-way splices.....................................................................240

6.3.3 Solder splices..........................................................240

6.3.3.1 Wire solder splices...................................................................240

6.3.3.2 Coaxial cable splices................................................................241

6.3.4 Poke-in splices........................................................241

6.3.4.1 Permanent poke-in splices.......................................................241

6.3.4.2 Removable poke-in splices......................................................241

6.3.5 Lever splices...........................................................241

6.3.5.1 Single-end lever splices...........................................................242

6.3.5.2 In-line lever splices..................................................................242

6.3.6 Twist-on splices (wire nuts)....................................242

Chapter 7 Wiring interconnects.............................243

7.1 Chapter introduction....................................243

7.1.1 Tidbits.....................................................................243

7.1.2 History of wiring interconnects..............................243

7.1.3 International glossary.............................................244

7.1.4 Selection, identification, and related classes..........244

7.1.4.1 AC power wiring interconnects selection................................245

7.1.4.2 Classes related to AC power interconnects..............................245

7.1.4.3 Classes related to terminal strips and boards...........................245

7.1.4.4 Classes related to through-panel parts.....................................245

7.1.4.5 AC power interconnect identification......................................246

7.1.5 Chapter orientation.................................................246

7.2 AC power wiring interconnects...................246

7.2.1 Compression interconnects.....................................247

7.2.1.1 Tubular compression lugs........................................................247

7.2.1.2 Grounding compression connectors.........................................248

7.2.1.3 Compression connector............................................................248

7.2.1.4 Aluminum compression adapters.............................................248

7.2.2 Splicing mechanical connectors.............................248

7.2.2.1 In-line splicer/reducer..............................................................249

7.2.2.2 Shear bolt connectors...............................................................249

7.2.2.3 Split bolts.................................................................................249

7.2.2.4 Parallel clamps.........................................................................249

7.2.3 Grounding mechanical connectors.........................249

7.2.3.1 Ground rod clamps...................................................................249

7.2.3.2 Lay-in ground lugs...................................................................249

7.2.3.3 Ground lugs..............................................................................249

7.2.4 AC wiring bars........................................................250

7.2.4.1 Insulated multi-tap connectors.................................................250

7.2.4.2 Neutral bar...............................................................................250

7.2.4.3 Ground bars..............................................................................250

7.2.5 Bus bars and straps.................................................250

7.2.5.1 Grounding bus bar....................................................................250

7.2.5.2 Jumper bus bar.........................................................................250

7.2.5.3 Ground straps...........................................................................250

7.3 Terminal strips and boards...........................251

7.3.1 Permanent terminal strips and boards....................251

7.3.1.1 Turret strips and boards............................................................251

7.3.1.2 Solder terminal strips...............................................................251

7.3.1.3 Ceramic tag strips....................................................................252

7.3.1.4 Punch-down blocks..................................................................252

7.4 Thru-panel wiring interconnects..................252

Table of Contents ix

7.4.1 Feedthroughs and penetrators.................................252

7.4.1.1 Feedthrough terminals.............................................................252

7.4.1.2 Subsea penetrators...................................................................252

7.4.1.3 Vacuum feedthroughs...............................................................252

7.5 Board-to-board permanent interconnects....253

7.5.1.1 Permanent board-to-board strip...............................................253

7.5.1.2 Lead strips................................................................................253

7.6 Cable junctions............................................253

7.6.1 Waterproof cable junctions.....................................253

Chapter 8 Junction and barrier blocks...................255

8.1 Chapter introduction....................................255

8.1.1 Tidbits.....................................................................255

8.1.2 History of junction and barrier blocks....................255

8.1.3 International glossary.............................................256

8.1.4 Selection, identification, and related classes..........256

8.1.4.1 Junction and barrier block selection........................................256

8.1.4.2 Junction and barrier block identification.................................256

8.1.4.3 Classes related to junction, barrier blocks...............................257

8.1.5 Chapter orientation.................................................257

8.2 Technical notes junction & barrier blocks...257

8.2.1 Wire termination.....................................................257

8.2.1.1 Simple wire termination...........................................................257

8.2.1.2 Tongue terminal termination....................................................258

8.2.1.3 Quick-connect disconnect termination....................................258

8.2.2 Current path............................................................258

8.3 Catalog of junction and barrier blocks.........259

8.3.1 Junction blocks, nuts, blocks and bars...................259

8.3.1.1 Junction posts...........................................................................259

8.3.1.2 Junction feedthroughs..............................................................260

8.3.1.3 Junction blocks.........................................................................260

8.3.1.4 Junction bars............................................................................260

8.3.2 Barrier blocks.........................................................260

8.3.2.1 Panel-mount barrier blocks......................................................261

8.3.2.2 Feedthrough barrier blocks......................................................261

8.3.2.3 PCB barrier blocks...................................................................262

8.3.2.4 Barrier block accessories.........................................................262

8.4 Screw terminal strips and boards.................262

Chapter 9 Terminal blocks....................................263

9.1 Chapter introduction....................................263

9.1.1 Tidbits.....................................................................263

9.1.2 History of terminal blocks......................................263

9.1.3 International glossary.............................................264

9.1.4 Selection, identification, and related classes..........265

9.1.4.1 Terminal block selection..........................................................266

9.1.4.2 One-piece terminal block identification...................................266

9.1.4.3 Pluggable terminal block identification...................................266

9.1.4.4 Other classes related to terminal blocks...................................267

9.1.5 Chapter orientation.................................................268

9.2 Technical notes, terminal blocks..................268

9.2.1 Terminal blocks for specific applications...............268

9.2.1.1 Terminal blocks in AC power applications..............................268

9.2.1.2 Terminal blocks for thermocouples..........................................269

9.2.2 Wire termination in wire cages...............................269

9.2.2.1 Wire preparation for terminal blocks.......................................269

9.2.2.2 Terminal block sizes.................................................................269

9.2.3 Variable length terminal blocks..............................269

9.3 Panel terminal blocks...................................270

9.3.1 Tubular terminal strips, blocks...............................270

9.3.1.1 Europa-style terminal strips.....................................................270

9.3.1.2 Pluggable Europa-style strips..................................................271

9.3.1.3 Quick-spring terminal blocks...................................................272

9.3.2 Flush-panel-mount terminal blocks........................272

9.3.2.1 Modular panel-mount terminal blocks.....................................272

9.3.2.2 US power distribution terminal blocks....................................272

9.3.2.3 EU power distribution terminal blocks....................................273

9.3.2.4 Monolithic panel-mount terminal blocks.................................273

9.3.3 Feedthrough terminal blocks..................................273

9.3.3.1 Modular, feedthrough terminal blocks.....................................273

9.3.3.2 Monolithic feedthrough terminal blocks..................................274

9.3.4 Rail mount terminal blocks....................................275

9.3.4.1 DIN rail terminal block mounting............................................275

9.3.4.2 Termination of rail-mounted blocks.........................................276

9.3.4.3 Assembly of rail-mounted modular blocks..............................276

9.3.4.4 Pitch of rail-mounted modular blocks......................................277

9.3.4.5 Types of rail-mounted terminal blocks....................................277

9.3.4.6 12GX1.5 cable termination......................................................278

9.3.4.7 Rail-mounted terminal block accessories................................278

9.3.4.8 Rail-mounted monoblocks.......................................................279

9.4 PCB terminal blocks....................................279

9.4.1 PCB terminal block characteristics........................279

9.4.1.1 PCB terminal block wire termination......................................279

9.4.1.2 PCB terminal block wire entry................................................280

9.4.1.3 PCB terminal block pitch.........................................................280

9.4.1.4 PCB terminal block circuits and levels....................................281

9.5 Pluggable terminal blocks............................281

9.5.1 Pluggable terminal block characteristics................282

9.5.1.1 Pluggable terminal block gender.............................................282

9.5.1.2 Pluggable plug wire entry orientation......................................282

9.5.1.3 Pluggable block header orientation..........................................283

9.5.1.4 Pluggable terminal block rows, levels.....................................283

9.5.1.5 Pluggable block polarization and coding.................................284

9.5.1.6 Pluggable terminal block fastening..........................................285

9.5.2 Pluggable shrouded terminal blocks.......................285

9.5.2.1 Pluggable terminal blocks, 2.5 mm..........................................285

9.5.2.2 Pluggable terminal blocks, 3.5 mm..........................................285

9.5.2.3 Pluggable terminal blocks, 3.81 mm........................................287

9.5.2.4 Pluggable terminal blocks, 5 mm.............................................288

9.5.2.5 Pluggable terminal blocks, 5.08 mm........................................291

9.5.2.6 Pluggable terminal blocks, 7.5 mm..........................................291

9.5.2.7 Pluggable terminal blocks 7.62mm..........................................291

9.5.2.8 Large pluggable terminal blocks..............................................292

9.5.3 Shroudless pluggable terminal blocks....................292

9.5.3.1 3.5 mm shroudless pluggable blocks.......................................292

9.5.3.2 5 mm shroudless pluggable blocks..........................................293

9.5.3.3 Misc. shroudless terminal blocks.............................................293

9.6 Misc. mount terminal blocks.......................293

9.6.1 Transformer terminal blocks..................................293

9.6.2 In-line terminal blocks............................................293

9.6.2.1 Single-ended terminal strips....................................................294

9.6.2.2 In-line pluggable terminal blocks............................................294

Chapter 10 Board-in interconnects........................295

10.1 Chapter introduction..................................295

10.1.1 Tidbits...................................................................295

10.1.2 History of board-in interconnects.........................295

10.1.3 International glossary...........................................295

10.1.4 Selection, identification, and related classes........295

10.1.4.1 Board-in selection and related classes...................................296

10.1.4.2 Board-in interconnect identification......................................296

10.1.4.3 Board-in interconnect classification......................................296

10.1.5 Chapter orientation...............................................297

10.2 Board-in terminals.....................................297

10.2.1 Board-in wire terminals........................................297

10.2.1.1 Permanent board-in wire terminals........................................297

x The electronic connector book

10.2.1.2 Separable board-in wire terminals.........................................298

10.2.2 Board-in cable terminals......................................299

10.2.2.1 Board-in FFC terminals.........................................................299

10.2.3 Board-in PCB terminals.......................................299

10.2.3.1 Poke-in board-in PCB terminals............................................299

10.2.3.2 IDT board-in PCB terminals..................................................299

10.2.3.3 Solder board-in PCB terminals..............................................300

10.2.3.4 Wire-wrap board-in PCB terminals.......................................300

10.3 Board-in wire terminators and blocks........300

10.3.1 Board-in wire terminators....................................300

10.3.1.1 Board-in crimp terminators....................................................300

10.3.1.2 Board-in IDT terminators......................................................300

10.3.2 Board-in wire blocks............................................301

10.3.2.1 Board-in open IDT blocks.....................................................301

10.3.2.2 Board-in button IDT blocks...................................................301

10.3.2.3 Board-in mass-terminated blocks..........................................301

10.3.2.4 Board-in poke-in blocks.........................................................301

10.3.2.5 Board-in solder strips.............................................................301

10.4 Board-in cable terminators and blocks......302

10.4.1 Board-in ribbon cable terminators and blocks.....302

10.4.1.1 Transition connectors.............................................................302

10.4.1.2 Ribbon cable traps..................................................................302

10.4.2 Board-in coaxial cable terminators and blocks....302

10.4.2.1 Board-in coaxial cable terminators........................................302

10.4.2.2 Board-in coaxial cable blocks................................................303

Chapter 11 Device sockets....................................305

11.1 Chapter introduction..................................305

11.1.1 Tidbits...................................................................305

11.1.2 History of device sockets......................................305

11.1.3 International glossary...........................................306

11.1.4 Selection, identification, and related classes........307

11.1.5 Chapter orientation...............................................307

11.2 Fuse clips, blocks, and holders..................308

11.2.1 Fuse socket terminology.......................................308

11.2.1.1 Fuse socket types...................................................................308

11.2.1.2 Fuse blocks vs. fuse holders...................................................309

11.2.1.3 Ferrule vs. cartridge fuse........................................................309

11.2.2 Fuse socket considerations...................................310

11.2.2.1 Should fuses be placed in sockets?........................................310

11.2.2.2 Fuse replaceability vs. shock safety.......................................310

11.2.2.3 Fuses require sockets.............................................................310

11.2.2.4 Making your own fuse block.................................................310

11.2.2.5 Fuse thermal management.....................................................310

11.2.2.6 Fuse failure / missing indicator..............................................310

11.2.3 Fuse socket characteristics....................................311

11.2.3.1 Fuse and socket current ratings..............................................311

11.2.3.2 Fuse and socket voltage ratings..............................................311

11.2.3.3 Fuse and socket environmental ratings..................................311

11.2.3.4 Fuse and socket mechanical ratings.......................................311

11.2.3.5 Fuse types and sizes...............................................................311

11.2.4 Fuse socket selection and related classes.............312

11.2.4.1 Fuse socket selection guide....................................................312

11.2.4.2 Fuse socket identification.......................................................312

11.2.4.3 Classes related to fuse sockets...............................................313

11.2.5 Cartridge fuse sockets...........................................314

11.2.5.1 Ferrule fuse clips....................................................................314

11.2.5.2 Ferrule fuse blocks.................................................................315

11.2.5.3 In-line ferrule fuse holders.....................................................315

11.2.5.4 PCB ferrule fuse holders........................................................315

11.2.5.5 Bulkhead ferrule fuse holders................................................316

11.2.5.6 Rail-mount ferrule fuse holders.............................................316

11.2.5.7 Blade cartridge fuse blocks....................................................316

11.2.5.8 Large cartridge fuse studs and lugs........................................316

11.2.6 Automotive fuse sockets.......................................317

11.2.6.1 Automotive blade fuse sockets...............................................317

11.2.6.2 Automotive prismatic fuse blocks..........................................318

11.2.6.3 Automotive high current fuse sockets....................................318

11.2.7 Other fuse sockets.................................................318

11.2.7.1 SMD brick fuse clips and blocks...........................................318

11.2.7.2 Radial fuse blocks and holders...............................................319

11.2.7.3 Edison base fuse blocks.........................................................319

11.2.7.4 Marine-rated battery fuse blocks............................................319

11.3 Cell, battery clips, holders, connectors......319

11.3.1 Cell and battery socket considerations.................320

11.3.1.1 Cell and battery types.............................................................320

11.3.1.2 Cell vs. battery.......................................................................320

11.3.1.3 Protection from reverse installation.......................................320

11.3.1.4 Custom battery holders..........................................................320

11.3.1.5 Li-ion safety concerns............................................................320

11.3.1.6 Vehicle reliability concerns....................................................320

11.3.2 Cell/battery socket selection, related classes........321

11.3.2.1 Cell and battery socket selection guide..................................321

11.3.2.2 Cell and battery socket identification.....................................321

11.3.2.3 Classes related to cell and battery sockets.............................321

11.3.3 Cell and battery socket catalog.............................321

11.3.3.1 Coin cell contacts, retainers, and holders...............................321

11.3.3.2 Cylindrical cell contacts and holders.....................................322

11.3.3.3 9 V battery snaps, holders, connectors...................................322

11.3.3.4 12 V battery terminals............................................................323

11.4 Semiconductor sockets and plugs..............323

11.4.1 Semi socket selection, related classes..................323

11.4.1.1 Semiconductor socket selection guide...................................323

11.4.1.2 Semiconductor socket identification......................................323

11.4.1.3 Classes related to semiconductor sockets..............................323

11.4.2 Transistor sockets.................................................324

11.4.3 IC sockets.............................................................324

11.4.3.1 DIP sockets.............................................................................324

11.4.3.2 ZIF DIP sockets......................................................................325

11.4.3.3 SOIC ZIF sockets...................................................................325

11.4.3.4 PLCC sockets.........................................................................326

11.4.3.5 TQFP ZIF sockets..................................................................326

11.4.3.6 Grid array IC ZIF sockets......................................................326

11.4.3.7 Misc. sockets..........................................................................327

11.4.4 DIP plugs..............................................................327

11.4.4.1 DIP ribbon cable plugs...........................................................327

11.4.4.2 DIP component carriers..........................................................328

11.4.4.3 Male-to-male adapters............................................................328

11.4.4.4 IC adapters.............................................................................328

11.5 Card edge sockets......................................329

11.5.1 Card edge socket selection, related classes..........329

11.5.1.1 Card applications....................................................................329

11.5.1.2 Card edge socket selection guide...........................................330

11.5.1.3 Card edge socket identification..............................................330

11.5.1.4 Classes related to card edge sockets......................................330

11.5.2 Card edge characteristics......................................330

11.5.2.1 Card edge shape.....................................................................330

11.5.2.2 Card edge rows and readouts.................................................331

11.5.2.3 Card edge pitch......................................................................331

11.5.2.4 Card edge circuits...................................................................332

11.5.3 Card edge socket, mating characteristics..............332

11.5.3.1 Acceptable card thicknesses...................................................333

11.5.3.2 Card edge socket coding and sections....................................333

11.5.3.3 Card locking and support.......................................................334

11.5.3.4 Card-edge socket rows and readouts......................................334

11.5.3.5 Card edge socket contacts......................................................335

11.5.3.6 Card edge insertion force.......................................................336

11.5.4 Card edge socket, termination characteristics......336

11.5.4.1 Board-mounted card edge sockets.........................................336

11.5.4.2 Panel-mounted card edge sockets..........................................337

11.5.4.3 Termination of card edge plugs..............................................338

11.5.5 Application-specific card edge sockets................338

11.5.5.1 Sockets for memory cards......................................................338

11.5.5.2 Card edge sockets for card racks............................................338

11.5.5.3 Card edge sockets for standard buses....................................338

Table of Contents xi

11.5.5.4 Card edge sockets for power supplies....................................339

11.5.5.5 Card edge sockets for solid state lighting..............................340

11.5.5.6 Card edge sockets for medical test strips...............................340

11.5.6 Card edge plugs....................................................340

11.5.6.1 RAST 2.5 card edge plugs.....................................................340

11.5.6.2 Other card edge plugs............................................................340

11.5.7 Card edge males and interposers..........................341

11.5.7.1 Male mates for card edge sockets..........................................341

11.5.7.2 Card edge double-ended sockets............................................341

11.6 FFC/FPC sockets.......................................341

11.6.1 FFC socket selection, related classes....................341

11.6.1.1 FFC/FPC socket selection guide............................................341

11.6.1.2 FFC socket identification.......................................................342

11.6.1.3 Classes related to FFC sockets...............................................342

11.6.2 FFC/FPC considerations.......................................342

11.6.2.1 Cable types.............................................................................342

11.6.2.2 FFC jumper options...............................................................342

11.6.2.3 FPC tail shape........................................................................343

11.6.2.4 FPC pads................................................................................343

11.6.3 FFC/FPC socket considerations...........................343

11.6.3.1 Types of FFC/FPC sockets.....................................................343

11.6.3.2 Latched FPC sockets..............................................................344

11.6.3.3 FFC/FPC entry orientation, contacts......................................345

11.6.3.4 Socket and cable circuit numbering.......................................345

11.6.3.5 FFC circuit order reversal......................................................346

11.6.3.6 Vertical socket PCB terminals................................................347

11.6.3.7 FFC/FPC pitch, thickness compatibility................................347

11.6.3.8 Socket compatibility with cable types...................................348

11.6.3.9 Sockets for shielded FFC.......................................................348

11.6.3.10 FFC/FPC socket termination................................................349

11.6.3.11 Proper mating assurance......................................................349

11.6.3.12 FFC/FPC socket comparison...............................................349

11.6.4 LIF FFC/FPC sockets...........................................350

11.6.5 Snap-in FPC sockets.............................................350

11.6.6 ZIF FFC/FPC sockets...........................................351

11.6.6.1 Slider FFC/FPC sockets.........................................................352

11.6.6.2 Front-flip FFC/FPC socket.....................................................352

11.6.6.3 Back-flip FFC/FPC socket.....................................................353

11.6.7 FPC jackets and sockets.......................................353

11.7 Other device sockets..................................354

11.7.1 Computer card sockets.........................................354

11.7.2 Ribbon cable sockets............................................355

11.7.3 Electric component sockets..................................356

11.7.3.1 Lamp sockets..........................................................................356

11.7.3.2 Vacuum tube sockets..............................................................356

11.7.3.3 Relay sockets..........................................................................357

11.7.3.4 Switch sockets........................................................................357

11.7.3.5 Crystal resonator sockets.......................................................358

11.7.3.6 LED strip sockets and splices................................................358

11.7.3.7 PCB clips................................................................................358

Chapter 12 Compression interconnects.................359

12.1 Chapter introduction..................................359

12.1.1 Tidbits...................................................................359

12.1.2 History of compression interconnects..................359

12.1.3 International glossary...........................................359

12.1.4 Selection, identification, and related classes........360

12.1.4.1 Compression interconnects selection.....................................360

12.1.4.2 Compression interconnect identification...............................360

12.1.4.3 Classes related to compression inter......................................360

12.1.5 Chapter orientation...............................................361

12.2 Catalog of compression interconnects.......361

12.2.1 Spring-loaded interconnects.................................361

12.2.1.1 Pogo pins................................................................................361

12.2.1.2 Pogo headers..........................................................................362

12.2.1.3 Test fixture probes..................................................................362

12.2.1.4 Compression coax board-to-board.........................................365

12.2.1.5 PCB springs...........................................................................365

12.2.1.6 PCB spring leaves..................................................................365

12.2.1.7 Spring leaf PCB headers........................................................366

12.2.1.8 Spring-loaded targets.............................................................366

12.2.2 EMI shielding products........................................366

12.2.2.1 EMI shielding resilient materials...........................................366

12.2.2.2 EMI finger stock....................................................................366

12.2.3 Direct wire-to-board plugs...................................367

12.2.3.1 Direct plugs to pads...............................................................367

12.2.3.2 Direct to PCB plugs...............................................................367

12.2.3.3 Direct clips to castellations....................................................368

12.2.4 Direct board-to-board interconnects.....................368

12.2.4.1 Elastomeric strips...................................................................368

12.2.4.2 Single piece mezzanine interposers.......................................369

12.2.5 LED strip interconnects........................................369

12.2.5.1 LED strip direct-mating plugs...............................................370

12.2.5.2 LED strip splices....................................................................370

Chapter 13 Shroudless strips.................................371

13.1 Chapter introduction..................................371

13.1.1 Tidbits...................................................................371

13.1.2 History of shroudless strips..................................371

13.1.2.1 “AmpModu”, “Berg”, and “DuPont”.....................................371

13.1.2.2 Other companies....................................................................372

13.1.3 International glossary...........................................372

13.1.4 Selection, identification, and related classes........372

13.1.4.1 Shroudless strip connectors selection....................................372

13.1.4.2 Shroudless strip identification...............................................372

13.1.4.3 Classes related to shroudless strips........................................372

13.1.5 Chapter orientation...............................................373

13.2 Technical notes, shroudless strips..............373

13.2.1 Shroudless strip characteristics............................373

13.2.1.1 Shroudless strip sizes.............................................................373

13.2.1.2 Shroudless strip intermateability...........................................373

13.2.1.3 “Two orientations” of right-angle strips................................374

13.2.1.4 Shroudless rectangular connectors contrast...........................374

13.2.2 Applications of shroudless strips..........................374

13.3 Catalog of shroudless strips.......................376

13.3.1 Shroudless strip PCB headers...............................376

13.3.1.1 Shroudless strip male headers................................................376

13.3.1.2 Shroudless strip female headers.............................................377

13.3.1.3 Shroudless strip stackers........................................................378

13.3.2 Shroudless strip plugs...........................................378

13.3.2.1 Male and female shroudless strip plugs.................................378

13.3.2.2 Conversion to rectangular connectors....................................379

13.3.3 Programming jumpers/shunts...............................379

13.3.4 Solid-state shroudless strips.................................380

13.3.4.1 LED strip plugs......................................................................380

13.3.4.2 LED strip adapters.................................................................380

13.3.4.3 LED lamp connectors............................................................380

Chapter 14 Rectangular connectors......................381

14.1 Chapter introduction..................................381

14.1.1 Tidbits...................................................................381

14.1.2 History of rectangular connectors........................381

14.1.2.1 Wire-to-wire...........................................................................381

14.1.2.2 Wire-to-board.........................................................................382

14.1.2.3 Board-to-board.......................................................................382

14.1.2.4 Appliance...............................................................................382

14.1.2.5 Automotive.............................................................................383

14.1.3 International glossary...........................................383

14.1.4 Selection, identification, and related classes........383

14.1.4.1 Rectangular connectors selection...........................................383

xii The electronic connector book

14.1.4.2 Rectangular connector identification.....................................384

14.1.4.3 Automotive connector identification......................................384

14.1.4.4 Classes related to board-to-board conn..................................384

14.1.4.5 Classes related to wire-to-wire conn......................................384

14.1.4.6 Classes related to wire-to-board conn....................................385

14.1.5 Chapter orientation...............................................385

14.2 Technical notes, rectangular connectors....386

14.2.1 Parts of a rectangular connector...........................386

14.2.2 Contact arrangement, numbering.........................386

14.2.2.1 Single-row arrangement, numbering.....................................386

14.2.2.2 Multi-row arrangement, numbering.......................................387

14.2.2.3 Hybrid positions arrangement, numbering............................388

14.2.3 Polarization, keying, and coding..........................388

14.2.3.1 Polarization............................................................................388

14.2.3.2 Keying and coding.................................................................390

14.2.4 Fastening of rectangular connectors.....................391

14.3 Board-to-board connectors........................391

14.3.1 Board-to-board connectors topologies.................391

14.3.1.1 Parallel topologies, mezzanine...............................................392

14.3.1.2 Perpendicular topologies, backplane.....................................393

14.3.1.3 Perpendicular topologies, orthogonal....................................395

14.3.1.4 Coplanar topology..................................................................396

14.3.1.5 Tilted topologies....................................................................396

14.3.1.6 Connectors for each topology................................................396

14.3.2 Technical notes, board-to-board connectors.........397

14.3.2.1 Mated height..........................................................................397

14.3.2.2 Misalignment, blind mating...................................................397

14.3.2.3 Board-to-board polarity.........................................................397

14.3.3 Low profile mezzanine connectors.......................397

14.3.3.1 Single-beam mezzanine connectors.......................................398

14.3.3.2 Dual-beam, inner-contact mezzanine.....................................398

14.3.3.3 Dual-beam, outer-contact mezzanine.....................................399

14.3.3.4 Standard dual-beam mezzanine connectors...........................399

14.3.3.5 Hybrid dual-beam mezzanine connectors..............................399

14.3.4 Small genderless board-to-board connectors.......400

14.3.4.1 C-E vs. C-T cross-section......................................................400

14.3.4.2 Unpolarized board-to-board connectors................................400

14.3.4.3 Polarized board-to-board connectors.....................................401

14.3.4.4 Pegged board-to-board connectors........................................401

14.3.4.5 Special contacts board-to-board conn....................................401

14.3.4.6 Floating board-to-board connectors.......................................401

14.3.4.7 Other genderless board-to-board conn...................................402

14.3.5 Small gendered board-to-board connectors..........402

14.3.5.1 Classic single-row board-to-board conn................................402

14.3.5.2 SMC rectangular connectors..................................................402

14.3.5.3 Partitioned board-to-board connectors...................................402

14.3.5.4 Self-mate board-to-board connectors.....................................403

14.3.5.5 Misc. small gendered board-to-board....................................403

14.3.6 Array board-to-board connectors..........................403

14.3.6.1 DIN 41612 connectors...........................................................403

14.3.6.2 High-density b-to-b connectors..............................................405

14.3.6.3 Hard metric board-to-board connectors.................................405

14.3.6.4 Misc. gendered array b-to-b connectors.................................407

14.3.6.5 Genderless array board-to-board............................................407

14.3.7 Blade board-to-board connectors.........................408

14.3.7.1 Parallel-blade board-to-board connectors..............................408

14.3.7.2 Coplanar-blades board-to-board conn....................................408

14.3.7.3 Split-blade board-to-board connectors...................................409

14.3.7.4 Battery blade board-to-board connectors...............................409

14.3.7.5 Solid-state lighting blade connectors.....................................409

14.3.8 Misc. board-to-board connectors..........................410

14.3.8.1 Vintage shroudless card cage connectors...............................410

14.3.8.2 Other b-to-b connectors.........................................................411

14.4 General-purpose connectors......................411

14.4.1 Prismatic connectors.............................................412

14.4.1.1 Unlatched prismatic crimp connectors...................................413

14.4.1.2 Prismatic connector derivatives.............................................414

14.4.1.3 FFC-terminated prismatic connectors....................................415

14.4.1.4 Narrow ribbon cable prismatic connectors............................415

14.4.1.5 Bump IDC..............................................................................415

14.4.1.6 Latched prismatic crimp connectors......................................418

14.4.1.7 Miniflex connectors...............................................................418

14.4.2 Pin-and-socket connectors....................................419

14.4.2.1 Pin-and-socket contacts.........................................................419

14.4.2.2 Pin-and-socket housings........................................................420

14.4.2.3 Pin-and-socket positions arrangement...................................420

14.4.3 Partitioned face rectangular connectors...............421

14.4.3.1 Rounded partition connectors................................................422

14.4.3.2 Mini Fit partitioned connectors..............................................423

14.4.3.3 Mini Fit connector variants....................................................424

14.4.3.4 Micro Fit connectors..............................................................425

14.4.3.5 Other “Fit” derivatives...........................................................425

14.4.3.6 Misc. partitioned face connectors..........................................425

14.4.4 Single-wall connectors.........................................426

14.4.4.1 3.96 mm single-wall connectors............................................426

14.4.4.2 2.54 mm single-wall connectors............................................427

14.4.4.3 CPU fan connectors...............................................................427

14.4.4.4 Single-wall connector position numbering............................428

14.4.4.5 Single-wall connectors with missing pins.............................428

14.4.4.6 Single-wall other than wire-to-board.....................................429

14.4.5 Small wire-to-board connectors...........................429

14.4.5.1 Low profile connector definition...........................................429

14.4.5.2 Low-profile headers...............................................................429

14.4.5.3 Low-profile plugs...................................................................431

14.4.5.4 Low-profile connector polarization.......................................432

14.4.5.5 Low-profile connector fastening............................................432

14.4.5.6 Low profile connector compatibility.....................................433

14.4.5.7 Low-profile sidelined connectors..........................................433

14.4.5.8 Parallel-mate connectors........................................................434

14.4.6 Full-size regular connectors.................................435

14.4.6.1 Metrimate / Trident connectors..............................................435

14.4.6.2 Dynamic / JFA connectors.....................................................436

14.4.6.3 Wire-to-wire connectors.........................................................437

14.4.7 Irregular gendered rectangular conn.....................437

14.4.7.1 Shroudless polarized wire-to-board conn..............................438

14.4.7.2 Other irregular rectangular connectors..................................438

14.4.8 Genderless rectangular connectors.......................438

14.4.8.1 LVDS connectors...................................................................438

14.4.8.2 Magnetic Pogo rectangular connectors..................................440

14.4.8.3 Other genderless rectangular connectors...............................440

14.5 Application-specific connectors.................440

14.5.1 Appliance connectors...........................................440

14.5.1.1 Standard Timer sockets..........................................................441

14.5.1.2 Faston boots...........................................................................441

14.5.1.3 RAST 5 connectors................................................................441

14.5.2 Automotive connectors.........................................441

14.5.2.1 Automotive connector contacts..............................................442

14.5.2.2 Automotive Terminal Position Assurance..............................444

14.5.2.3 Automotive connector keying................................................445

14.5.2.4 Automotive connector sealing................................................445

14.5.2.5 Automotive connector latching, coupling..............................445

14.5.2.6 Automotive connector mount.................................................446

14.5.2.7 Wire-to-wire automotive connectors......................................446

14.5.2.8 Wire-to-board automotive connectors....................................447

14.5.2.9 CAN bus distribution blocks..................................................447

14.5.2.10 Automotive RF connectors..................................................447

14.5.2.11 High-current EV connectors................................................448

14.5.2.12 2.8mm “automobile” connectors.........................................448

14.5.2.13 SAE J1239 connectors, derivatives......................................448

14.5.3 Hot-pluggable connectors.....................................449

14.5.3.1 SATA hot-pluggable connectors.............................................449

14.5.3.2 SFF-8087 hot-pluggable connectors......................................450

14.5.3.3 SAS/PCIe hot-pluggable connectors......................................450

14.5.3.4 SFP hot-pluggable connectors...............................................450

14.5.3.5 Misc. hot-pluggable connectors.............................................451

14.5.4 RC model power connectors................................451

14.5.4.1 Bullet-type RC model connectors..........................................452

14.5.4.2 Other RC model connectors...................................................453

14.5.5 Misc. application-specific connectors..................454

14.5.5.1 Sensor connectors..................................................................454

Table of Contents xiii

14.5.5.2 High voltage connectors........................................................454

14.5.5.3 Thermocouple connectors......................................................454

14.5.5.4 Power tool battery connectors................................................455

14.5.5.5 Lighting fixture connectors....................................................455

Chapter 15 Single-circuit connectors....................457

15.1 Chapter introduction..................................457

15.1.1 Tidbits...................................................................457

15.1.2 History of single-circuit connectors.....................457

15.1.2.1 Binding posts.........................................................................457

15.1.2.2 Banana connectors.................................................................458

15.1.2.3 RC bullets...............................................................................458

15.1.2.4 Quick-connect disconnects....................................................458

15.1.3 International glossary...........................................458

15.1.4 Selection, identification, and related classes........459

15.1.4.1 Single-circuit connectors selection........................................459

15.1.4.2 Single-circuit connectors identification.................................460

15.1.4.3 Classes related to single-circuit connectors...........................460

15.1.5 Chapter orientation...............................................460

15.2 Disconnects................................................461

15.2.1 Quick-connect disconnects...................................461

15.2.1.1 Quick-connect catalog...........................................................461

15.2.1.2 0. 250" quick-connects...........................................................461

15.2.1.3 “Locking” quick-connect plugs.............................................462

15.2.1.4 Quick-connect adapters..........................................................463

15.2.2 Other disconnects.................................................463

15.2.2.1 Packard 56..............................................................................463

15.2.2.2 Bullet disconnects..................................................................463

15.2.2.3 Knife disconnects...................................................................463

15.2.2.4 Snap disconnects....................................................................463

15.3 Naked-pin connectors................................464

15.3.1 Banana connectors and binding posts..................464

15.3.1.1 Binding posts.........................................................................464

15.3.1.2 Banana connectors.................................................................464

15.3.1.3 Banana variants......................................................................465

15.3.2 Small naked-pin connectors.................................465

15.3.2.1 Tip connectors........................................................................465

15.3.2.2 Wander plugs..........................................................................466

15.3.2.3 Board pins and wire sockets..................................................466

15.3.2.4 Board-to-board. wire-to-board connectors.............................466

15.3.3 Large naked-pin connectors.................................466

15.3.3.1 RC bullet connectors..............................................................466

15.3.3.2 Radsok connectors.................................................................467

15.4 Unipole connectors....................................467

15.4.1 Technical notes, unipole connectors.....................467

15.4.1.1 Shielded unipole connectors..................................................467

15.4.1.2 Unipole latching.....................................................................468

15.4.2 Signal unipole connectors....................................468

15.4.2.1 Pin-and-socket unipole connectors........................................468

15.4.2.2 Slim metal unipole connectors...............................................468

15.4.2.3 Rubber unipole connectors....................................................468

15.4.2.4 Surface electrode connectors.................................................468

15.4.3 High-power unipole connectors...........................468

15.4.3.1 PowerPole connectors............................................................468

15.4.3.2 Camlock connectors...............................................................469

15.4.3.3 Powerlock connectors............................................................470

15.4.3.4 Energy storage connectors.....................................................471

15.4.3.5 Large metal unipole connectors.............................................471

15.4.3.6 High-current plastic unipolar.................................................472

15.4.3.7 Solar panel connectors, MC4.................................................472

15.4.3.8 Misc. high-power unipole connectors....................................472

Chapter 16 Concentric connectors........................473

16.1 Chapter introduction..................................473

16.1.1 Tidbits...................................................................473

16.1.2 History of concentric connectors..........................474

16.1.2.1 Phone connector.....................................................................474

16.1.2.2 Cigarette lighter connector.....................................................475

16.1.2.3 Phono connector.....................................................................475

16.1.2.4 Coax barrel power plug..........................................................475

16.1.3 International glossary...........................................475

16.1.4 Selection, identification, and related classes........475

16.1.4.1 Concentric connectors selection............................................476

16.1.4.2 Concentric connector identification.......................................476

16.1.4.3 Classes related to concentric connectors................................476

16.1.5 Chapter orientation...............................................477

16.2 Catalog of concentric connectors...............477

16.2.1 Phone connectors..................................................477

16.2.1.1 1/4-inch Phone connectors.....................................................477

16.2.1.2 Phone connectors variants......................................................478

16.2.1.3 Miniature Phone connectors..................................................478

16.2.2 Coax barrel power couplers..................................479

16.2.2.1 Standard coax barrel power couplers.....................................480

16.2.2.2 EIAJ coax barrel power couplers...........................................481

16.2.2.3 CCTV coax barrel power coupler..........................................481

16.2.2.4 Coax barrel power coupler variants.......................................482

16.2.3 Other concentric connectors.................................482

16.2.3.1 Phono (RCA) connectors.......................................................483

16.2.3.2 Cigarette lighter connectors...................................................484

16.2.3.3 Coplanar concentric connectors.............................................484

16.2.3.4 Flush concentric connectors...................................................485

16.2.3.5 Misc. concentric connectors...................................................485

16.2.4 Concentric adapters..............................................485

Chapter 17 Coax connectors.................................487

17.1 Chapter introduction..................................487

17.1.1 Tidbits...................................................................487

17.1.2 History of coax/RF connectors.............................488

17.1.3 International glossary...........................................489

17.1.4 Selection, identification, and related classes........489

17.1.4.1 Coax connectors selection......................................................489

17.1.4.2 Coax connector identification................................................490

17.1.4.3 Classes related to coax connectors.........................................490

17.1.5 Chapter orientation...............................................491

17.2 Technical notes, coax connectors...............491

17.2.1 Coax connector electrical characteristics.............491

17.2.1.1 Coax connector characteristic impedance..............................492

17.2.1.2 Coax connector cutoff frequency...........................................494

17.2.1.3 Coax connector power handling............................................494

17.2.1.4 Coaxial cable power handling................................................495

17.2.1.5 Coax connector insertion loss................................................495

17.2.2 Coaxial connector mechanical characteristics......496

17.2.2.1 Gender of coax connectors.....................................................496

17.2.2.2 Reverse polarity coax connectors..........................................496

17.2.2.3 Parts of a coax connector.......................................................496

17.2.2.4 Shield/fastener separation......................................................497

17.2.2.5 Mating vs. shield diameter.....................................................498

17.2.2.6 Coaxial connector mating cycles...........................................498

17.2.2.7 Coaxial connector fastening and coupling.............................498

17.2.2.8 Keying of coax connectors.....................................................499

17.2.3 Coaxial-terminated plugs, receptacles..................499

17.2.3.1 Coax plugs.............................................................................499

17.2.3.2 Panel-mount coax receptacles................................................500

17.2.3.3 Coaxial cable compatibility...................................................501

17.2.4 PCB-mount coax connectors................................502

17.3 Catalog of coax/RF connectors..................502

17.3.1 Interior RF connectors..........................................502

17.3.1.1 Miniature RF cable-to-board connectors...............................503

17.3.2 Microwave connectors.........................................503

17.3.2.1 Blind-mate microwave connectors........................................504

xiv The electronic connector book

17.3.2.2 Large microwave connectors.................................................505

17.3.2.3 SMA microwave connectors, derivatives..............................505

17.3.2.4 Medium microwave connectors.............................................506

17.3.2.5 SMB microwave connectors, derivatives..............................507

17.3.2.6 Small microwave connectors.................................................508

17.3.3 Standard exterior RF connectors..........................509

17.3.3.1 Belling Lee.............................................................................509

17.3.3.2 UHF connector and derivatives.............................................509

17.3.3.3 N-type connectors and derivatives.........................................510

17.3.3.4 BNC connectors.....................................................................510

17.3.3.5 BNC derivative connectors....................................................511

17.3.3.6 TNC connectors and derivatives............................................512

17.3.3.7 F-type connector....................................................................512

17.3.3.8 Other TV and video coax connectors.....................................512

17.3.3.9 Telecom RF connectors..........................................................513

17.3.3.10 Misc, standard RF connectors..............................................514

17.3.4 Atypical exterior RF connectors...........................514

17.3.4.1 Genderless, self-mate RF connectors.....................................514

17.3.4.2 Mobile antenna connectors....................................................515

17.3.4.3 High-power EIA flange RF connectors..................................515

17.3.4.4 Slim coax connectors.............................................................516

17.3.5 Non-RF coax connectors......................................516

17.3.5.1 Twinax connectors.................................................................516

17.3.5.2 Triax connectors.....................................................................517

17.3.5.3 High voltage coax connectors................................................517

17.4 Coaxial ancillary components....................517

17.4.1 Coax couplers, adapters, and splitters..................518

17.4.1.1 Coax couplers.........................................................................518

17.4.1.2 Coax splitters.........................................................................519

17.4.1.3 Between series coax adapters.................................................519

17.4.2 Coax terminators and attenuators.........................519

17.4.3 Coax accessories...................................................520

17.5 Waveguide flanges.....................................520

Chapter 18 Circular connectors.............................523

18.1 Chapter introduction..................................523

18.1.1 Tidbits...................................................................523

18.1.2 History of circular connectors..............................524

18.1.2.1 Starting in California..............................................................524

18.1.2.2 Meanwhile, in Europe............................................................524

18.1.2.3 And in Asia.............................................................................524

18.1.3 International glossary...........................................525

18.1.4 Selection, identification, and related classes........525

18.1.4.1 Circular connectors selection.................................................525

18.1.4.2 Circular connector identification...........................................526

18.1.4.3 Classes related to circular connectors....................................526

18.1.5 Chapter orientation...............................................527

18.2 Technical notes, circular connectors..........527

18.2.1 Circular connector characteristics........................527

18.2.1.1 Circular connector mount......................................................527

18.2.1.2 Parts of a circular connector..................................................528

18.2.1.3 Contact arrangement and numbering.....................................529

18.2.1.4 Circular connector polarization..............................................530

18.2.2 Circular connector mating....................................532

18.2.2.1 Scooping................................................................................532

18.2.2.2 Circular connector fastening, coupling..................................532

18.3 General-purpose circular connectors.........532

18.3.1 XLR circular connectors and derivatives.............532

18.3.1.1 XLR circular connectors........................................................533

18.3.1.2 XLR derivatives.....................................................................533

18.3.1.3 XLR-NLE AC power connectors...........................................534

18.3.1.4 Mini-XLR circular connectors...............................................534

18.3.2 DIN-type circular connectors...............................534

18.3.2.1 Tuchel circular connectors.....................................................534

18.3.2.2 DIN circular connectors.........................................................534

18.3.2.3 Mini-DIN circular connectors................................................536

18.3.2.4 Mini-DIN connector derivatives............................................537

18.3.2.5 Power DIN.............................................................................538

18.3.3 MIL-spec circular connectors...............................538

18.3.3.1 MIL-spec arrangement, numbering.......................................539

18.3.3.2 MIL-DTL-38999 connectors.................................................540

18.3.4 CPC and CMC circular connectors......................543

18.3.4.1 CPC circular connectors........................................................543

18.3.4.2 CMC circular connectors.......................................................544

18.3.5 Classic metal circular connectors.........................544

18.3.5.1 GX metal circular connectors................................................545

18.3.5.2 CNR01/‘P’ metal circular connectors....................................545

18.3.5.3 XS metal circular connectors.................................................547

18.3.6 IEC industrial circular connectors........................547

18.3.6.1 IEC connector technical notes...............................................547

18.3.6.2 7/8" circular connectors.........................................................549

18.3.6.3 M5 and M8 IEC circular connectors......................................550

18.3.6.4 M12 IEC circular connectors.................................................550

18.3.6.5 Large IEC circular connectors...............................................552

18.3.6.6 Industrial motor IEC circular connectors...............................554

18.3.6.7 NMEA 2000 circular connectors...........................................554

18.3.7 Slim circular connectors.......................................555

18.3.7.1 Metal shell slim circular connectors......................................555

18.3.7.2 Plastic shell slim circular connectors.....................................556

18.3.7.3 Medical slim circular connectors...........................................557

18.3.7.4 High-density push-pull connectors........................................557

18.3.8 Tri-eco power circular connectors........................558

18.3.9 X-style circular connectors...................................558

18.3.10 Plastic power circular connectors.......................559

18.3.10.1 RD24 circular connectors....................................................559

18.3.10.2 Bulgin Buccaneer connectors..............................................560

18.3.10.3 SP plastic circular connectors..............................................560

18.3.11 Micro/nano circular connectors..........................561

18.3.12 Proprietary circular connectors..........................561

18.3.12.1 WeiPu circular connectors...................................................561

18.3.12.2 Push-button latch circular connectors..................................562

18.4 Application-specific connectors.................562

18.4.1 Lighting circular connectors.................................562

18.4.1.1 LED lighting..........................................................................562

18.4.1.2 Accent lighting circular connectors.......................................564

18.4.1.3 Stage lighting circular connectors..........................................564

18.4.2 E-bike connectors.................................................565

18.4.2.1 E-bike signal connectors........................................................565

18.4.2.2 E-bike motor connectors........................................................566

18.4.2.3 E-bike battery connectors......................................................566

18.4.2.4 E-bike charger connectors......................................................566

18.4.3 Automotive circular connectors............................567

18.4.3.1 HSD circular connectors........................................................567

18.4.3.2 ISO 15170 circular connectors...............................................567

18.4.3.3 Harsh environment circular connectors.................................568

18.4.3.4 Misc. automotive circular connectors....................................568

18.4.3.5 Traction battery circular connectors.......................................568

18.4.3.6 Tractor trailer connectors.......................................................568

18.4.4 Other transportation circular connectors..............569

18.4.4.1 Aviation circular connectors..................................................569

18.4.4.2 Railway circular connectors...................................................569

18.4.5 Immersion circular connectors.............................569

18.4.5.1 Dry-mate immersion circular connectors...............................570

18.4.5.2 Wet-mate immersion circular connectors..............................570

18.4.5.3 Downhole circular connectors...............................................571

18.4.6 Industrial circular connectors...............................571

18.4.6.1 Explosion-proof circular connectors......................................571

18.4.6.2 Nuclear radiation circular connectors....................................571

18.4.6.3 Vacuum circular connectors...................................................571

18.4.6.4 Base station circular connectors.............................................572

18.4.6.5 Ethernet circular connectors..................................................572

18.5 Irregular circular connectors......................572

18.5.1 Shroudless circular connectors.............................573

18.5.1.1 Vintage shroudless circular connectors..................................573

18.5.1.2 Circle hex connectors.............................................................573

Table of Contents xv

18.5.1.3 DIN speaker connectors.........................................................573

18.5.2 Genderless circular connectors.............................573

18.5.2.1 Pogo-pin communication equipment.....................................573

18.5.2.2 Magnetic circular connectors.................................................574

18.5.2.3 speakOn public address connectors.......................................574

18.5.2.4 Misc. genderless circular connectors.....................................575

18.5.3 Circular connectors with sub-connectors.............575

18.5.3.1 Compound circular connectors..............................................575

18.5.3.2 Data I/O circular connectors..................................................575

Chapter 19 Exterior signal connectors..................577

19.1 Chapter introduction..................................577

19.1.1 Tidbits...................................................................577

19.1.2 History of exterior signal connectors...................577

19.1.2.1 Telephone connector history..................................................577

19.1.2.2 D-shell connector history.......................................................578

19.1.2.3 Data I/O connector history.....................................................578

19.1.3 International glossary...........................................578

19.1.4 Selection, identification, and related classes........579

19.1.4.1 Exterior signal connector selection........................................579

19.1.4.2 Exterior connector signal identification.................................579

19.1.4.3 Classes related to exterior signal conn...................................579

19.1.5 Chapter orientation...............................................579

19.2 D-shell connectors.....................................580

19.2.1 Genderless D-shell connectors.............................580

19.2.1.1 Micro-Ribbon connectors......................................................580

19.2.1.2 Mini-D ribbon connectors......................................................581

19.2.1.3 Shrunk-D ribbon connectors..................................................581

19.2.2 Gendered D-shell connectors...............................581

19.2.2.1 D-sub connectors...................................................................582

19.2.2.2 Micro-D connectors...............................................................585

19.2.2.3 Nano-D connectors................................................................585

19.2.2.4 Other gendered D-shell connectors........................................586

19.3 Telephone and modular connectors...........586

19.3.1 Vintage telephone connectors...............................586

19.3.2 Modular connectors, registered jack....................587

19.3.2.1 Modular plugs and jacks........................................................587

19.3.2.2 Registered Jack and modular notation...................................588

19.3.2.3 Circular modular connectors..................................................588

19.3.2.4 Modular connector derivatives..............................................588

19.4 Data I/O connectors...................................589

19.4.1 USB connectors....................................................589

19.4.1.1 USB host and device..............................................................589

19.4.1.2 Standard USB connectors......................................................590

19.4.1.3 USB variants..........................................................................592

19.4.1.4 Proprietary USB connectors..................................................593

19.4.2 Other data I/O connectors.....................................593

19.4.2.1 eSata.......................................................................................594

19.4.2.2 HDI........................................................................................594

19.4.2.3 ix industrial............................................................................595

19.4.2.4 Firewire IEEE1394................................................................595

19.4.2.5 Lightning................................................................................595

19.4.2.6 Thunderbolt............................................................................595

19.4.3 Video I/O connectors............................................595

19.4.3.1 DisplayPort............................................................................595

19.4.3.2 DVI........................................................................................597

19.4.3.3 HDMI.....................................................................................597

19.4.3.4 SCART...................................................................................597

19.5 Misc. exterior signal connectors................597

19.5.1.1 Magnetic Pogo connectors.....................................................598

19.5.1.2 Home theater speaker connectors..........................................598

Chapter 20 Exterior power connectors..................599

20.1 Chapter introduction..................................599

20.1.1 Tidbits...................................................................599

20.1.2 History of exterior power connectors...................599

20.1.2.1 US AC power connector history............................................599

20.1.2.2 German AC power connector history....................................600

20.1.2.3 UK AC power connector history............................................600

20.1.2.4 DC power connector history..................................................600

20.1.3 International glossary...........................................601

20.1.4 Selection, identification, and related classes........602

20.1.4.1 Exterior power connector selection.......................................602

20.1.4.2 Exterior power connector identification................................602

20.1.4.3 Classes related to exterior power conn..................................602

20.1.5 Chapter orientation...............................................602

20.2 AC power connectors.................................603

20.2.1 AC power connector terminology........................603

20.2.1.1 Outlet, inlet, and plug.............................................................603

20.2.1.2 Genders..................................................................................604

20.2.1.3 Coupler...................................................................................604

20.2.1.4 Prong......................................................................................604

20.2.1.5 Grounded vs. grounding.........................................................604

20.2.1.6 Pole........................................................................................604

20.2.1.7 Parts of an AC power connector............................................605

20.2.2 AC power connector termination.........................605

20.2.2.1 AC power polarity..................................................................605

20.2.2.2 AC wire color code................................................................606

20.2.3 Consumer AC power connectors..........................606

20.2.3.1 Why so many different plugs?...............................................606

20.2.3.2 Country connector type codes................................................608

20.2.3.3 CEE 7 and Type C, E, F connectors.......................................609

20.2.3.4 NEMA and Type A, B connectors..........................................611

20.2.3.5 UK and Type G connectors....................................................612

20.2.3.6 Denmark and Type K connectors...........................................613

20.2.3.7 Thailand Type O connectors..................................................613

20.2.3.8 Israel and Type H connectors.................................................613

20.2.3.9 Australia, Argentina, and Type I conn....................................613

20.2.3.10 Switzerland and Type J connectors......................................613

20.2.3.11 Italian and Type L connectors..............................................614

20.2.3.12 India, South Africa and Types D, M....................................614

20.2.3.13 South Africa, Brazil, and Type N.........................................614

20.2.3.14 Multi-standard outlets..........................................................614

20.2.3.15 AC power adapters...............................................................615

20.2.4 NEMA industrial AC connectors..........................615

20.2.4.1 NEMA standard high-power connectors................................617

20.2.4.2 NEMA twist-lock connectors.................................................618

20.2.5 Pin-and-sleeve AC power connectors...................619

20.2.5.1 NEMA Pin-and-sleeve connectors.........................................619

20.2.5.2 IEC 60309 Pin-and-sleeve connectors...................................619

20.2.6 Appliance AC coupler..........................................621

20.2.6.1 Vintage appliance couplers....................................................621

20.2.6.2 IEC 60320 appliance couplers...............................................621

20.2.6.3 Power entry modules..............................................................624

20.2.7 Industry-specific AC power connectors...............624

20.2.7.1 Public address, powerCON connectors..................................624

20.2.7.2 Other stage AC power connectors..........................................624

20.2.7.3 EV charging connectors.........................................................624

20.2.8 Weird AC connectors............................................626

20.3 DC power connectors................................627

20.3.1 DC couplers..........................................................627

20.3.2 Electric vehicle DC connectors............................627

20.3.2.1 Anderson Power SB battery connectors.................................627

20.3.2.2 Euro Battery Connector.........................................................628

20.3.2.3 E-bike DC charging connectors.............................................628

20.3.2.4 Golf cart charging connectors................................................629

Chapter 21 Industrial connectors..........................631

21.1 Chapter introduction..................................631

21.1.1 Tidbits...................................................................631

21.1.2 History of industrial connectors...........................631

xvi The electronic connector book

21.1.3 International glossary...........................................632

21.1.4 Selection, identification, and related classes........632

21.1.4.1 Industrial connector identification.........................................633

21.1.4.2 Industrial selection and related classes..................................633

21.1.5 Chapter orientation...............................................634

21.2 Heavy-duty connectors..............................634

21.2.1 Heavy-duty connector introduction......................634

21.2.1.1 Sizes.......................................................................................634

21.2.1.2 Family members.....................................................................635

21.2.1.3 Power Earth............................................................................635

21.2.1.4 EMI shielding.........................................................................636

21.2.1.5 Heavy-duty connector sealing................................................636

21.2.2 Heavy-duty connector housings...........................636

21.2.2.1 Latching and fastening...........................................................637

21.2.2.2 Hoods.....................................................................................637

21.2.2.3 Bases......................................................................................638

21.2.2.4 Standalone covers..................................................................638

21.2.2.5 Coupling hoods......................................................................638

21.2.2.6 Cable glands...........................................................................638

21.2.2.7 DIN rail mount.......................................................................638

21.2.2.8 Docking frames......................................................................639

21.2.2.9 Explosion-proof heavy-duty connectors................................639

21.2.3 Heavy-duty connector inserts...............................639

21.2.3.1 Group B monoblock inserts...................................................639

21.2.3.2 Group A monoblock inserts...................................................640

21.2.3.3 Modular frames and inserts....................................................641

21.2.4 Heavy-duty connector accessories.......................642

21.2.4.1 Crimp contacts.......................................................................642

21.2.4.2 Coding accessories.................................................................642

21.2.5 Proprietary heavy-duty connectors.......................642

21.3 Other industrial connectors........................643

21.3.1 Industrial valve sockets........................................643

21.3.2 Vintage rectangular connectors............................643

21.3.2.1 Cinch Jones connectors..........................................................643

21.3.2.2 Vintage pin and fork connectors............................................644

21.3.2.3 DIN 41618 and DIN 41622 connectors.................................644

21.3.2.4 Vintage diagonal fork connectors..........................................644

21.3.3 Drawer connectors................................................644

21.3.3.1 Shroudless gendered drawer connectors................................645

21.3.3.2 Genderless drawer connectors...............................................645

21.3.3.3 Shrouded gendered drawer connectors..................................645

21.3.3.4 Drawer connector frames.......................................................646

21.3.3.5 Avionics drawer connectors...................................................646

21.3.4 Terminal Junction Systems...................................647

21.3.4.1 Terminal Junction Systems introduction................................647

21.3.4.2 Rail-mount terminal junction modules..................................648

21.3.4.3 Solder terminal junction modules..........................................648

21.3.4.4 Panel-mount terminal junctions.............................................648

21.3.4.5 Terminal junction plugs.........................................................648

21.3.4.6 Terminal junction splices.......................................................648

Chapter 22 Multiple-class interconnects...............649

22.1 Chapter introduction..................................649

22.2 Catalog of multi-class interconnects..........649

22.2.1 Breakouts..............................................................649

22.2.1.1 Breakout boards.....................................................................649

22.2.1.2 Terminal block adapters.........................................................649

22.2.2 Adapters................................................................650

22.2.2.1 Adapters within a family........................................................650

22.2.2.2 Adapters within a class...........................................................650

22.2.2.3 Adapters between classes.......................................................650

22.2.3 Misc. multi-class interconnects............................651

Chapter 23 Non-electric components....................653

23.1 Chapter introduction..................................653

23.1.1 Chapter orientation...............................................653

23.2 Fiber-optic connectors...............................653

23.3 Accessories................................................654

23.3.1 Connector accessories..........................................654

23.3.1.1 Keystone connector plates.....................................................654

23.3.1.2 Connector frames...................................................................654

23.3.1.3 Ferrite plates...........................................................................654

23.3.2 Cable accessories..................................................654

23.3.2.1 Cable grommets, bushings, and glands..................................654

23.3.2.2 Board-in ribbon cable guides.................................................655

Part C - Usage.......................................................656

Chapter 24 Design.................................................657

24.1 Chapter introduction..................................657

24.1.1 Chapter orientation...............................................657

24.2 Electrical design.........................................657

24.2.1 Tips.......................................................................657

24.2.1.1 Design for manufacturability.................................................657

24.2.1.2 Design for reliability..............................................................657

24.2.1.3 Flexible pinout assignment....................................................658

24.2.1.4 Design to avoid user misconnections.....................................658

24.2.1.5 Direct wire-to-PCB soldering................................................658

24.2.2 Schematic diagrams..............................................658

24.2.2.1 Schematic diagram symbols..................................................658

24.2.2.2 Schematic diagram designators..............................................659

24.2.3 PCB design for connectors...................................660

24.2.3.1 Through-hole interconnects...................................................660

24.2.3.2 Press-fit interconnects............................................................661

24.2.3.3 Surface mounted interconnects..............................................661

24.2.3.4 End-launch RF connectors.....................................................662

24.2.4 Card edge design..................................................663

24.2.4.1 Card outline............................................................................663

24.2.4.2 Two-sided card copper layers................................................664

24.2.4.3 Bilevel card copper layers......................................................665

24.3 Qualification testing...................................665

24.3.1 Electrical qualification testing..............................666

24.3.1.1 Contact resistance test............................................................666

24.3.1.2 Contact current and temperature test.....................................666

24.3.1.3 Hipot connector testing..........................................................666

24.3.1.4 RF connector testing..............................................................666

24.3.2 Mechanical qualification testing..........................666

24.3.2.1 Vibration tests........................................................................666

24.3.2.2 Environmental tests................................................................667

24.3.2.3 Wire/cable pull tests...............................................................667

Chapter 25 Assembly............................................669

25.1 Chapter introduction..................................669

25.1.1 Chapter orientation...............................................669

25.2 General tips................................................669

25.2.1 Interconnect procurement.....................................669

25.2.2 Test fixtures for cable assemblies.........................670

25.2.3 Manufacturing standards......................................670

25.3 Wire/cable preparation, termination..........670

25.3.1 Wire cutting and stripping....................................670

25.3.1.1 Manual wire cutting...............................................................670

25.3.1.2 Manual wire stripping............................................................671

25.3.1.3 Wire-cutting and stripping machine.......................................671

25.3.2 Wire soldering......................................................672

25.3.2.1 Soldering safety.....................................................................672

25.3.2.2 Wire tinning...........................................................................672

Table of Contents xvii

25.3.2.3 Tall-wall solder cups..............................................................673

25.3.2.4 Flush-top solder cups.............................................................673

25.3.2.5 Bifurcated terminals...............................................................674

25.3.2.6 Slotted terminals....................................................................674

25.3.2.7 Solder eyelets.........................................................................674

25.3.2.8 Turrets....................................................................................675

25.3.2.9 Common solder inspection items...........................................675

25.3.3 Wire crimping.......................................................675

25.3.3.1 Crimping tools.......................................................................675

25.3.3.2 Crimping tips.........................................................................676

25.3.3.3 Open barrel crimp..................................................................677

25.3.3.4 Closed barrel crimp................................................................678

25.3.3.5 Insulated barrel crimp............................................................678

25.3.3.6 Ferrule crimp..........................................................................679

25.3.3.7 Punch-down blocks................................................................679

25.3.4 Other permanent wire terminations......................680

25.3.4.1 Ultrasonic welding.................................................................680

25.3.4.2 Wire wrapping........................................................................680

25.3.5 Wire termination to a screw..................................680

25.3.5.1 Stripped wire termination to a plain screw............................680

25.3.5.2 Ring terminal termination to a plain screw............................681

25.3.5.3 Fork terminal termination to a plain screw............................681

25.3.5.4 Wire termination to a captive-plate screw.............................681

25.3.6 Wire termination to a clamp.................................681

25.3.6.1 Wire clamp termination..........................................................681

25.3.7 Wire termination to a wire cage...........................682

25.3.7.1 Stripped wire termination to a cage.......................................682

25.3.7.2 Poke-in termination................................................................682

25.3.7.3 Terminal in a wire cage..........................................................682

25.3.8 Wire termination protection..................................682

25.3.8.1 Heat shrink tubing..................................................................682

25.3.8.2 Regular tubing........................................................................683

25.3.9 Cable preparation.................................................683

25.3.9.1 Control cable preparation.......................................................683

25.3.9.2 Braided shield cable preparation............................................683

25.3.9.3 Foil shield cable preparation..................................................683

25.4 PCB and panel mount................................684

25.4.1 PCB-mount...........................................................684

25.4.1.1 Through-hole manufacturing.................................................684

25.4.1.2 Surface mount manufacturing................................................684

25.4.1.3 Conformal coating.................................................................684

25.4.1.4 Module potting.......................................................................684

25.4.1.5 Press-fit manufacturing..........................................................684

25.4.2 Panel mounting.....................................................685

25.4.2.1 Flush-panel mounting............................................................685

25.4.2.2 Through-panel mounting.......................................................685

25.5 Interconnect assembly...............................685

25.5.1 Terminal termination............................................685

25.5.1.1 Broaching fastener installation..............................................685

25.5.2 Wire splice termination........................................685

25.5.2.1 Crimp wire splices.................................................................686

25.5.2.2 IDT wire splices.....................................................................686

25.5.2.3 Solder wire splices.................................................................687

25.5.2.4 Poke-in wire splices...............................................................687

25.5.2.5 Lever wire splices..................................................................687

25.5.3 AC power wiring termination...............................688

25.5.3.1 Grounding compression splice...............................................688

25.5.3.2 Tubular compression lugs......................................................688

25.5.3.3 Splicing mechanical connectors.............................................688

25.5.3.4 Grounding mechanical connectors.........................................689

25.5.3.5 AC power bars........................................................................689

25.5.3.6 Waterproof cable junctions....................................................689

25.5.4 Junction and barrier block termination.................690

25.5.4.1 Junction post, feedthrough.....................................................690

25.5.4.2 Junction bar............................................................................690

25.5.4.3 Wire to captive-plate panel-mount barrier block...................690

25.5.4.4 Terminal to PCB barrier block...............................................691

25.5.5 Terminal block termination..................................691

25.5.5.1 Feedthrough terminal blocks..................................................691

25.5.5.2 PCB terminal blocks..............................................................692

25.5.5.3 Pluggable terminal blocks......................................................692

25.5.5.4 Rail-mount terminal block.....................................................692

25.5.6 Board-in interconnect termination........................693

25.5.6.1 Board-in wire terminal...........................................................693

25.5.6.2 Board-in crimp terminator.....................................................695

25.5.6.3 Board-in IDT PCB terminals.................................................695

25.5.6.4 Open board-in IDT blocks.....................................................696

25.5.6.5 Board-in button IDT blocks...................................................696

25.5.6.6 Mass-terminated board-in IDT blocks...................................697

25.5.6.7 Board-in IDT terminators......................................................697

25.5.6.8 Direct ribbon cable termination to a PCB..............................698

25.5.6.9 Transition connector...............................................................698

25.5.6.10 Ribbon cable socket or wire trap.........................................699

25.5.7 Device sockets assembly......................................699

25.5.7.1 Fuse sockets...........................................................................699

25.5.7.2 Cell and battery sockets.........................................................699

25.5.7.3 Semiconductor sockets...........................................................699

25.5.7.4 Computer card sockets...........................................................699

25.5.7.5 Card edge sockets..................................................................699

25.5.7.6 FFC sockets............................................................................700

25.5.8 Compression interconnects assembly...................700

25.5.8.1 Spring-loaded interconnects...................................................700

25.5.8.2 Test fixture probes..................................................................701

25.5.8.3 RedFit SKEDD plugs.............................................................701

25.5.8.4 SKEDD terminal blocks........................................................701

25.5.8.5 Elastomeric (Zebra) strips......................................................701

25.5.8.6 Single-piece mezzanine interposers.......................................701

25.5.9 Shroudless strips assembly...................................701

25.5.9.1 Shroudless strip plug assembly..............................................701

25.5.10 Rectangular connector assembly........................702

25.5.10.1 Small wire-to-board crimp plug...........................................702

25.5.10.2 Rectangular IDT plugs.........................................................702

25.5.10.3 RAST plug...........................................................................703

25.5.10.4 Prismatic plug......................................................................703

25.5.10.5 Connectors with round contacts...........................................703

25.5.10.6 Bump IDC plug....................................................................704

25.5.10.7 JAE MX34 automotive plug termination.............................705

25.5.10.8 Molex MX150L automotive plug termination.....................705

25.5.10.9 Deutsch automotive plug termination..................................706

25.5.10.10 Sealed automotive plug termination..................................706

25.5.10.11 Pull-to-seat plug termination..............................................707

25.5.10.12 Automotive plug mating/unmating....................................707

25.5.10.13 RC model plug...................................................................707

25.5.11 Single-circuit connectors assembly....................707

25.5.11.1 Banana plug termination......................................................707

25.5.11.2 Unipole connector termination.............................................708

25.5.11.3 Anderson PowerPole termination.........................................708

25.5.11.4 Camlock termination............................................................708

25.5.12 Concentric connector assembly..........................708

25.5.12.1 Phone plug termination........................................................708

25.5.12.2 Coaxial barrel power plug termination................................709

25.5.12.3 Zip-cord to a coaxial barrel power plug...............................709

25.5.12.4 Phono plug termination........................................................710

25.5.13 Coax connector assembly...................................710

25.5.13.1 Miniature coax cable-to-board mating/unmating.................710

25.5.13.2 Low-power coaxial cable termination.................................710

25.5.13.3 Coax connector mating........................................................712

25.5.13.4 Coax connector unmating....................................................713

25.5.13.5 High-power coax cable termination, testing........................713

25.5.14 Circular connector assembly..............................713

25.5.14.1 Circular connector, fixed contacts.......................................713

25.5.14.2 Circular connector, insertable contacts................................714

25.5.14.3 DIN plug termination...........................................................714

25.5.14.4 XLR plug termination..........................................................715

25.5.15 Exterior signal connector assembly....................715

25.5.15.1 Modular plug termination....................................................715

25.5.15.2 Control cable to a D-sub connector.....................................716

25.5.15.3 Ribbon cable to a D-shell plug.............................................716

25.5.16 Exterior power connector termination................717

25.5.16.1 AC power plug termination..................................................717

25.5.16.2 Pin and sleeve plug termination...........................................717

25.5.16.3 Anderson SB termination.....................................................718

xviii The electronic connector book

25.5.17 Industrial connector assembly............................718

25.5.17.1 Termination to a heavy-duty plug........................................718

25.5.17.2 Heavy-duty crimp assembly................................................719

25.5.17.3 Heavy-duty base assembly...................................................719

Chapter 26 Maintenance.......................................721

26.1 Chapter introduction..................................721

26.2 Connector maintenance.............................721

26.2.1 Regular maintenance............................................721

26.2.1.1 Coax connector maintenance.................................................721

26.2.2 Lubrication...........................................................722

26.2.2.1 Shroud lubrication..................................................................722

26.2.2.2 Contact lubrication.................................................................722

26.3 Repair.........................................................722

26.3.1 Connector repair...................................................722

26.3.1.1 Repair tools............................................................................722

26.3.1.2 Consumer product receptacle repair......................................723

26.3.1.3 Crimped contact repair...........................................................724

26.3.1.4 FFC/FPC socket repair...........................................................724

26.3.1.5 Elastomeric strip repair..........................................................724

26.3.1.6 Card edge repair.....................................................................724

26.3.2 Contact extraction.................................................724

26.3.2.1 Shroudless and prismatic plug contact extraction..................724

26.3.2.2 Single-wall plug contact extraction.......................................724

26.3.2.3 Low-profile plug contact extraction.......................................725

26.3.2.4 Round contact extraction.......................................................725

26.3.2.5 CPC CMC connector contact extraction................................725

26.3.2.6 Mini fit plug contact extraction..............................................725

26.3.2.7 Automotive plug contact extraction.......................................725

26.3.2.8 D-sub contact extraction........................................................726

26.3.2.9 Quick-connect extraction.......................................................727

26.3.2.10 Coax plug center contact extraction.....................................727

26.3.2.11 Anderson genderless contact extraction...............................727

26.3.2.12 NEMA AC power contact extraction...................................727

26.3.2.13 Heavy-duty connector contact extraction............................727

26.3.3 Cable assembly repair..........................................727

26.3.3.1 Data I/O plug, cable repair.....................................................728

26.3.3.2 AD adapter cord repair...........................................................728

26.3.3.3 FFC repair..............................................................................728

26.3.3.4 FPC repair..............................................................................728

26.4 Modification..............................................728

26.4.1 Wrong connector..................................................728

26.4.1.1 Wrong battery cable connector..............................................728

26.4.1.2 Wrong display cable connector..............................................728

26.4.1.3 Wrong USB cable..................................................................728

26.4.1.4 Wrong bus cable connectors..................................................728

26.4.2 Cable modification...............................................728

26.4.2.1 Interior cable extension..........................................................729

26.4.2.2 FFC reduction........................................................................729

26.4.3 Connector creation...............................................729

A Appendix...........................................................731

A.1 Terms............................................................731

A.2 Conductors for termination..........................731

A.2.1 Wire........................................................................731

A.2.1.1 Bus wire...................................................................................731

A.2.1.2 Hook-up wire...........................................................................731

A.2.1.3 Wire colors...............................................................................732

A.2.1.4 Litz wire...................................................................................732

A.2.1.5 Building wire............................................................................732

A.2.1.6 Battery and welding cable........................................................732

A.2.1.7 Application-specific wire.........................................................732

A.2.1.8 Magnet wire.............................................................................732

A.2.1.9 Braid.........................................................................................732

A.2.2 Cable.......................................................................732

A.2.2.1 Control cable............................................................................732

A.2.2.2 Control cable colors.................................................................733

A.2.2.3 Shielded cable..........................................................................733

A.2.2.4 Portable cord............................................................................733

A.2.2.5 Building cable..........................................................................733

A.2.2.6 Zip cord....................................................................................734

A.2.2.7 Flat telephone cable.................................................................734

A.2.2.8 Ribbon cable............................................................................734

A.2.2.9 Flexible Flat Cable (FFC)........................................................735

A.2.2.10 Flat cables and flex circuits comparison................................736

A.2.3 Coaxial cable..........................................................737

A.2.3.1 Standard coaxial cable.............................................................737

A.2.3.2 Specialty coaxial cable.............................................................737

A.2.3.3 High power coaxial cable.........................................................737

A.2.4 Boards.....................................................................738

A.2.4.1 Plain boards..............................................................................738

A.2.4.2 Copper-clad boards..................................................................738

A.2.4.3 Perfboards................................................................................738

A.2.4.4 Solderless breadboards.............................................................739

A.2.4.5 Printed Circuit Boards..............................................................739

A.2.4.6 Flexible Printed Circuits (FPC)...............................................739

A.2.4.7 Conductive Ink Circuit (CIC)..................................................740

A.2.4.8 Etched copper jumpers (ECJ)..................................................740

A.2.5 Other conductors....................................................740

A.2.5.1 Metal fasteners.........................................................................740

A.3 Custom connectors.......................................741

A.3.1 Full-custom connectors..........................................741

A.3.2 Semi-custom connectors.........................................741

A.4 Resources.....................................................742

A.4.1 Manufacturer’s pronunciation, meaning.................742

Acronyms and initialisms......................................743

Glossary and alphabetical index............................745

References.............................................................776

Preface

Why this book

Connectors get no respect. They are not as sexy as microcontrollers, which is why we have many books on microcontrollers

but hardly any on connectors. Yet connectors are just as crucial

and deserving of a book that discusses them in detail.

What this book is

This book is a practical guide for the user of interconnect components. Specifically:

• It explains each of 100-plus attributes that characterize interconnect components.

• It catalogs all the electrical interconnect components used in the electronic industry, describing each in some detail.

• It advises the selection, identification, inclusion into a design, assembly into a product, and repair.

This book is not an academic textbook, as it has no numbered equations, no exercises, and little scientific rigor. It is the first

book to cover the entire gamut of interconnect components. A few older books cover only some connectors but may do so in

greater technical detail; others speak to the connector designer

. Generally, a technical book that discusses specific interconnect

components becomes outdated because the industry changes rapidly. This is less of a concern with connectors because the

industry is mature. At the present rate, the families introduced in the next 20 years will represent only three percent of the

families introduced in the last century.

This book is a labor of love. The knowledge it may bring you is my only reward for the 4.5 years I spent writing it.

Intended audience

This book is for the design engineers who must select the appropriate interconnect components for their product, for the stock

managers who wonder what a “plug” is, for purchasing agents who want to know what they are ordering, for project managers,

repair and maintenance technicians. It expects the reader to have a basic understanding of technology. Multi-language glossaries

may help speakers of languages other than English. It is not for the engineer who designs connectors or works for the military-

industrial complex.

Style

This book’s writing style is dictated by logic, not Chicago

. Please don’t let the casual tone detract from the breadth of the

materials presented in this book and the depth of the research that went into it.

This edition

This first edition follows an unadvertised pre-release edition published in October 2023 with two incomplete chapters and

placeholder terminology. Feedback from some of its 200 readers is included in this edition.

About me

While I may not have a direct connection to the connector industry, I do have 50 years of experience in designing electronic

products for a variety of markets, a love for the art of electronic design, a deep fascination for connectors, a knack for taxonomy,

a desire to fill a void I see in this field, and experience writing technical books.

My interest in connectors was sparked in 1979 when my college roommate, Bruce Carey, told his stepfather, William Tiffany,

about my interest in electronics. William had been a representative for AMP, the granddaddy of connectors. He promptly sent me

a vintage storage trunk filled with his leftover samples. He was probably glad to get rid of them, but for me, that was a door

opening into the wide world of terminals and connectors. In the decades since then, I accumulated cabinets full of electronic

components and assemblies that have been great resources for the thousands of pictures in this book.

I knew a dentist who, when introduced to new people and shaking hands, would not look at their eyes but at their mouth to

1 As I write this, investigators are examining a terminal block that may have caused the Dali container ship to lose power and

crash into a bridge in Baltimore. Six workers on the bridge fell into the water and died.

2 Let me acknowledge these authors: Ed Wiseman, who, starting in 1967, published the ten volumes about MIL-spec

connectors, The Encyclopedia of Connectors; P. Antony Clayton, who published Handbook of Electronic Connectors in

1982; and the editors who, in the 1980s and 1990s, published various compilations of articles related to connectors.

3 I place punctuation where it makes logical sense, not where it looks pretty. I integrate bullet points within paragraphs and

use numbered lists only if order matters. I’m sorry for causing your inner copy editor to go into conniptions.

The Electronic Connector Book - online appendix

Table of contents