Electrical connectors date back to the early nineteenth century when Thomas Edison invented the light bulb. By the 1920s, the banana plug had become the most widely-used type of electrical connector. But, as technology advanced, the need for dependable and long-lasting electrical connectors increased exponentially. To accommodate increased industry demands, manufacturers created the D-Sub connector, followed by the AMP connector, designed to deliver a robust connection in harsh environments.
The primary purpose of modern electrical connectors is to provide a secure and reliable connection between two or more electrical components or circuits. Today, power connectors have safety ground connections and conductors to ensure power continuity while preventing electrical shorts. If you’re a novice in this field, then this comprehensive guide will help you choose the best connectors for your project.
Types of Electrical Connectors for Electronics
Connector configurations are made up of a housing and terminals case, which secure the connection and keep the contacts from shorting out. Manufacturers construct connectors from metal or plastic to offer a secure and dependable connection between two or more circuits.
The most common connector configuration is the male and female plug and socket, consisting of two or more metal contacts inserted into a mating connector. They come in various shapes and sizes, each with specific electrical applications, ranging from industrial machines to consumer electronics. The following are the primary categories of connector types that are optimized for different use cases:
Audio Electrical Connectors
These devices allow sound signals to be transmitted between two or more components and are created to give a secure and reliable connection for audio signals. Their applications range from home audio systems to professional recording studios. The most commonly used audio connectors include RCA connectors, 3.5 mm jacks, banana plugs, and XLR connectors. Each connector has a distinct design and provides varying levels of performance and durability.
Video Connectors
They are commonly used to transmit audio and video signals in analog video sources—like VCRs, DVD players, and game consoles—to displays like TVs, monitors, and projectors. Video connectors commonly used include RCA, S-Video, HDMI, DVI, DisplayPort, and VGA.
Power Connectors
These connectors transfer power supply between electrical devices such as computers, televisions, and other electronic equipment. Power connector types include barrels, AC plugs, and Molex connectors.
Data Connectors
They assist in safely collating data from various databases, files, analytics platforms, and other sources. Then they deliver it to a single predetermined destination. Data connectors are useful for integrating and synchronizing data from multiple sources, synchronizing data between systems, and integrating data from cloud-based systems. Other connector brands and cables include:
- Amphenol connectors
- TE Connectivity connectors
- Molex connectors
- Plug and socket connectors
- Industrial connectors
- Waterproof connectors
- High-speed connectors
- PCB connectors
- Panel-mount connectors
- Quick-disconnect connectors
- Crimp connectors
- Solder connectors
- Twist-lock connectors
All these are individual electrical connector types that can be distinguished by their function and termination ends, as discussed below.
Classification of Electrical Connectors
Electrical connectors are classified into the following three connector types based on their termination ends:
- Board-to-board connectors come in multiple shapes and connector sizes. They’re designed to offer reliable connections between two or more boards. They connect basic two-board systems to more complex circuit boards. Board-to-board connectors include pin-and-socket, solderless, press-fit, and wire-to-board.
- Cable/wire-to-cable/wire connectors are used as electrical, electronic, and computer connectors to secure two or more cable connectors or wires without soldering. Applications range from connecting power cords to electrical outlets, computers, audio, video, lighting systems, and automotive components.
- Cable/wire-to-board connectors help attach wires to electronic parts like printed circuit boards (PCBs). They provide a safe, dependable connection capable of handling high voltages. Wire-to-board connectors are commonly used in automotive, industrial, and consumer electronics applications. They also connect wires to LEDs, switches, and resistor components.
Factors to Consider When Choosing Connectors
Several factors must be considered when selecting electrical connectors, depending on the type and its intended application:
- Voltage rating: Confirm the connector has the appropriate rating for the voltage at hand.
- Current rating: Ensure the connector can withstand the current passed through it.
- Electrical connector size: Consider how much space your electrical terminals and connectors require.
- Electrical parameters: Connectors should clearly highlight electrical parameters like rated voltage and current.
- Materials used: Connectors typically have a metal or plastic conductor and an insulator. Conductivity, mechanical strength, formability, and resilience are all essential conductivity properties for electrical contacts.
- Environmental rating: Be sure the connector can withstand the environmental conditions to which it will be subjected. For example, hermetically-sealed or water-resistant connectors can stay fully functional underwater. They also protect connections from water pressure up to a certain depth.
- Matching Impedance: Controlling the flow of electricity across a circuit board results in the desired low voltage standing wave ratio (VSWR).
- Agency approvals: Electrical connector systems should meet the performance standards of Underwriter Laboratories (UL), the Society of Automotive Engineers (SAE), and the Compliance, Safety, and Accountability (CSA) organizations.
Avoid These Mistakes
Connectors are essential components of any electrical device. So picking the right electrical connector for your project and understanding its functionalities and capabilities is critical. Common mistakes to avoid when selecting and installing electrical connectors include:
- Incorrect bandwidth selection
- Choosing an inappropriate connector size
- Using a connector with the wrong impedance
- Utilizing an incorrect strip tool and crimp die
- Improperly positioning the center conductor or pin
- Failing to keep all braid strands away from the center conductor, as this can cause electrical shorts
Quality connectors are in high demand. It’s, therefore, crucial to source high-voltage connector manufacturers from a reputable marketplace search engine like Partstack. For example, Molex is considered the world’s largest manufacturer of connector products and systems.
How to Find the Right Connectors for Any Project
Connectors play a vital role in offering a secure and reliable connection between two or more circuits. When choosing electrical connectors, make sure they adhere to all safety standards to ensure proper design and functionality. Whether you need a connector for a specific application or a general-purpose connector, we have the right solution. We offer a range of high-quality connectors from top brands, including Amphenol, TE Connectivity, and Molex. Browse our connectors today and get connected!
References:
Choosing connectors: https://www.ept.ca/features/10-things-to-consider-when-selecting-the-a-connector/
Connector types: https://www.linquip.com/blog/common-types-of-electrical-connectors/
Connector classifications: https://connectorsupplier.com/connector-basics-three-types-of-electrical-connectors/#:~:text=Electrical%20connectors%20are%20classified%20into,wire%2Dto%2Dboard%20connectors
Convector mistakes: https://www.belden.com/blogs/smart-building/13-common-bnc-connector-installation-mistakes/
Connector manufacturers: https://www.linkedin.com/pulse/top-15-high-voltage-connector-manufacturers-?trk=pulse-article_more-articles_related-content-card
Partstack’s editorial team is made up technical writers and engineering folks from around the world.
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