Electrical Connectors Guide | Different Types & Benefits

What are circular electrical connectors?

Electrical connectors are essential components in a wide range of electronic and electrical systems, enabling the transfer of power and signals between different devices. By providing a reliable means of joining circuits, they enable communication and functionality across applications ranging from consumer electronics to industrial machinery.

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Among the many types of electrical connectors, circular connectors stand out for their robust design and user-friendly features. These connectors, including options like the 12-pin configuration, are specifically designed to deliver secure and efficient connections in space-constrained environments while offering protection against environmental factors such as moisture and dust.

The adaptability of electrical connectors makes them indispensable for applications requiring reliable and durable connections. Circular electrical connectors are available in various designs and pin configurations, tailored to accommodate diverse power and data transmission requirements. Thanks to their ability to maintain electrical integrity even in challenging conditions, they are a preferred choice for professionals seeking optimal performance and reliability in their systems.

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Overmoulded Cable Connectors

These connectors are fully encapsulated in a protective moulding, offering superior strain relief and excellent protection against environmental factors. Known for their durability, they withstand harsh conditions and deliver reliable, consistent performance over time. Another advantage is that they are ready for immediate use and can be connected directly without the need for complex assembly.

Use Case: Suitable for heavy-duty industrial applications or environments subject to frequent mechanical stress.

• Connecting cordsets (cable-to-cable connector): Designed to connect two cable ends, these connectors allow for quick extension or joining of cables. They provide flexibility in wiring systems that may need to be adapted or extended over time.
  Use Case: Applications requiring cable extensions or connections across long distances.
• Single ended cordsets: With a connector on one end and open wires on the other, single-ended cordsets simplify direct device connections to power or control systems. Their pre-configured design ensures quick installation and reliable performance, making them ideal for industrial and automation applications.
  Use Case: Ideal for direct device connections where quick and dependable wiring is required.

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2. Number of Contacts

The number of contacts in a connector indicates how many circuits it can support. It is essential to ensure that the connector has an adequate number of contacts to handle both the power and data signals required by your application.

• Low-Contact Connectors (2 to 4 contacts) are suitable for simple applications that only require power transmission or basic signal flow, such as in lighting, basic sensors, or low-power motor control. However, they can still transmit high data volumes, which can occurs via Ethernet protocols rather than purely digital signals.
• Medium-Contact Connectors (5 to 12 contacts) are common in industrial environments where both power and data need to be transferred, such as in automation systems, sensors, or industrial machinery. These provide more flexibility for signal and power segregation.
• High-Contact Connectors (13+ contacts) are used in complex systems like communication networks, multi-channel data acquisition, or high-performance computing systems. They enable transmission of a large volume of data and power through a single interface, supporting advanced control, monitoring, and communication protocols.

Important: The number of contacts also impacts the voltage and current that can be transmitted through the connector. A higher number of contacts results in smaller distances between the pins, allowing only lower voltages to be safely transmitted to avoid the risk of short circuits. Therefore, it is not always straightforward to classify connectors solely based on the number of contacts as either simple or complex. Factors such as transmission protocols, current and voltage requirements, and specific application conditions also play a crucial role. More info below.

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3. Gender (Pin/Socket)

Connectors consist of two components: a male element (pin) and a female element (socket). These can either be permanently installed or attached to the end of a cable. In practice, pins and sockets are always used together once the connection is established, making it challenging to classify their usage by application. However, there are certain tendencies: device connectors (panel mounts or flange parts) often feature a socket, while cables typically use a plug. Once the device is connected, both plug and socket are integral to the connection, e.g., a plug in the device and a socket on the cable.

• Male connectors typically have exposed pins, which can allow for easier contact during mating and faster signal transmission. Male connectors are often used in stationary or fixed components such as control panels, where they will not be exposed to damage from frequent handling.
• The sockets of female connectors offer protection for the internal contacts, reducing the risk of electrical shorts or accidental contact. In applications where accidental exposure to live parts could pose a risk such as high-voltage systems or areas where connectors might be touched), female connectors are safer because their sockets shield the live pins.

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6. Rated Voltage

The rated voltage indicates the maximum voltage that a connector can safely withstand. This is one of the most critical specifications to consider when selecting a connector, as it determines the electrical insulation and breakdown voltage the connector can handle without failure.

Voltage ratings can be specified for AC (Alternating Current) or DC (Direct Current) systems. Our product range spans from 24V to V. It is essential to ensure that the connector's rated voltage aligns with the voltage requirements of your application.

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7. Environmental and Temperature Range

It is essential to assess the IP rating (Ingress Protection) of the connector, which indicates its level of protection against dust and water, along with its ability to withstand temperature and other environmental factors. For connectors used in extreme conditions, such as high temperatures or heavy vibrations, ensure that the connector has an appropriate IP rating and environmental sealing features.

In harsh environments, such as medical or food processing applications, it is particularly important to select connectors with robust and hygienically safe seals to prevent breakage, contamination, or exposure to harmful substances.

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9. Wire Size / Wire Gauge

Ensure that the connector is compatible with the wire size or gauge that aligns with the current rating, especially when operating close to the maximum capacity for the connector type. This is a crucial consideration when selecting a circular electrical connector, as it directly impacts the connector's ability to handle current, voltage, and overall performance in the application.

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Choosing the correct wire size is vital to prevent issues such as overheating, voltage drops, and other inefficiencies that could jeopardise both safety and functionality. Wire sizes are typically measured using the standard American Wire Gauge (AWG) system.

• Smaller gauge numbers indicate thicker wires capable of carrying more current. This usually applies to power connectors used in industrial machinery that require lower gauge (thicker) wires, such as 10 AWG or 16 AWG.
• Larger gauge numbers represent thinner wires that are suited for lower current applications. For signal transmission or data lines, such as in sensors, telecommunications, or medical devices, higher gauge (thinner) wires like 24 AWG or 26 AWG are often used.

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If you're diving into PCB design, one of the most critical decisions you'll make is choosing the right connectors. Whether you're looking for PCB connector types, a connector selection guide, or specifics on board-to-board connectors, wire-to-board connectors, or RF connectors, this guide has you covered. We'll break down the essentials of each connector type, their applications, and tips for selecting the best option for your project. Let's explore everything you need to know to ensure reliable and efficient connections in your printed circuit board designs.

Why Connectors Matter in PCB Design

Connectors are the unsung heroes of PCB design. They create the vital links between components, boards, and external devices, ensuring seamless transmission of power, signals, and data. A poorly chosen connector can lead to signal loss, mechanical failure, or even complete system breakdowns. On the other hand, the right connector enhances performance, durability, and ease of assembly. With countless options available, understanding PCB connector types and their specific uses is the first step to a successful design.

What Are the Main Types of PCB Connectors?

PCB connectors come in various shapes, sizes, and configurations, each tailored for specific functions. Below, we’ll explore the most common types, focusing on their structure, purpose, and typical applications.

1. Board-to-Board Connectors

Board-to-board connectors are designed to link two PCBs together, often used in compact devices where space is limited. These connectors allow for direct communication between boards without the need for external wiring, reducing clutter and improving reliability.

• Key Features: Available in pin headers, sockets, and mezzanine styles. They often support high-density connections with pitch sizes as small as 0.4mm.
• Applications: Found in smartphones, tablets, and multi-board systems where stacking is necessary.
• Advantages: Compact design, high signal integrity, and support for high-speed data transfer (up to 10 Gbps in some cases).
• Considerations: Ensure proper alignment during assembly to avoid connection issues. Mating cycles (typically 10 to 100) should match the expected usage.

2. Wire-to-Board Connectors

Wire-to-board connectors facilitate connections between a wire or cable and a PCB. They are essential for bringing external power or signals into the board and are widely used across industries.

• Key Features: Often feature crimp terminals or insulation displacement contacts (IDC). Available in pitches ranging from 1.0mm to 5.08mm.
• Applications: Common in automotive systems, home appliances, and industrial equipment.
• Advantages: Easy to install and replace, with secure locking mechanisms to prevent disconnection.
• Considerations: Pay attention to current and voltage ratings (e.g., some handle up to 10A at 250V) to match your circuit's requirements.

3. RF Connectors

RF (Radio Frequency) connectors are specialized for high-frequency signals, typically in the range of 3 kHz to 300 GHz. They are built to maintain signal integrity with minimal loss or interference, making them crucial for communication devices.

• Key Features: Designed with controlled impedance (often 50 ohms or 75 ohms) to prevent signal reflection. Common types include SMA, BNC, and MCX connectors.
• Applications: Used in wireless devices, antennas, GPS modules, and test equipment.
• Advantages: Low signal loss and high-frequency performance (some support up to 18 GHz).
• Considerations: Choose connectors with proper shielding to avoid electromagnetic interference (EMI). Mating durability (often 500 cycles for SMA types) is also a factor.

4. Other Notable PCB Connector Types

Beyond the primary categories, several other connectors play vital roles in PCB design:

• Wire-to-Wire Connectors: Used to join two sets of wires without involving a PCB, often in power distribution systems.
• Edge Connectors: Found in plug-in cards, these connect directly to the edge of a PCB, common in older computer hardware with mating cycles around 25-50.
• Power Connectors: Designed for high-current applications, supporting up to 40A in some industrial setups.

A Connector Selection Guide for PCB Design

Selecting the right connector for your PCB design can feel overwhelming with so many options. However, focusing on a few key factors can simplify the process. This connector selection guide will help you make informed decisions tailored to your project needs.

1. Understand Your Electrical Requirements

Start by evaluating the electrical demands of your circuit:

• Current and Voltage: Ensure the connector can handle the required load. For example, a power connector for industrial use might need to support 20A at 600V, while a signal connector may only need 1A at 5V.
• Signal Type: For high-speed data or RF signals, prioritize connectors with low impedance mismatch and minimal insertion loss (e.g., under 0.5 dB for RF connectors).
• Frequency Range: RF connectors must match the frequency of your application. A connector rated for 6 GHz won’t perform well in a 12 GHz system.

2. Consider Mechanical Constraints

The physical aspects of your design also influence connector choice:

• Size and Pitch: In compact designs, opt for connectors with smaller pitches (e.g., 0.5mm for board-to-board connectors) to save space.
• Mating Cycles: If frequent connections and disconnections are expected, choose a connector with a high mating cycle rating (e.g., 100 cycles for wire-to-board connectors).
• Mounting Type: Decide between through-hole or surface-mount connectors based on your PCB assembly process. Surface-mount options are often preferred for automated production.

3. Evaluate Environmental Factors

The operating environment can impact connector performance:

• Temperature Range: Some connectors are rated for extreme conditions, such as -40°C to 105°C, ideal for automotive or outdoor applications.
• Moisture and Dust: For harsh environments, look for connectors with IP ratings (e.g., IP67 for waterproofing) to ensure reliability.
• Vibration and Shock: In applications like aerospace, connectors with locking mechanisms or rugged designs prevent disconnection under stress.

4. Budget and Availability

Cost and supply chain factors are practical considerations. High-performance connectors, such as those for RF applications, often come with a higher price tag (sometimes $5-$10 per unit compared to $0.50 for basic headers). Balance performance needs with budget constraints, and ensure the chosen connector is readily available to avoid production delays.

Suggested Reading: The Ultimate Guide to Selecting the Right Connectors for Your PCB Components

Best Practices for Integrating Connectors in PCB Design

Choosing the right connector is only part of the equation. Proper integration into your PCB layout is equally important for performance and reliability. Here are some best practices to follow:

• Optimize Placement: Position connectors near the edge of the board for easy access, especially for wire-to-board types. For board-to-board connectors, ensure alignment with mating boards.
• Minimize Signal Interference: For RF connectors, keep traces short and use ground planes to reduce EMI. Maintain a 50-ohm impedance path if possible.
• Secure Mechanical Stability: Use mounting holes or brackets for connectors under mechanical stress. This is crucial for heavy-duty power connectors handling currents above 10A.
• Test Thoroughly: Simulate your design under real-world conditions to check for signal integrity, thermal performance, and mechanical durability before production.

Common Challenges with PCB Connectors and How to Avoid Them

Even with careful planning, connector-related issues can arise. Here are some common challenges and tips to mitigate them:

• Signal Loss in RF Applications: Use connectors with low insertion loss and ensure proper impedance matching. Avoid sharp bends in traces near RF connectors.
• Mechanical Failure: Over-mating or misalignment can damage connectors. Choose designs with guiding features or higher mating cycle ratings for frequent use.
• Thermal Overload: High-current connectors can overheat if undersized. Select connectors with adequate current ratings and consider heat dissipation in your layout.

Future Trends in PCB Connector Technology

The world of PCB connectors is evolving rapidly to meet the demands of modern electronics. Here are a few trends to watch:

• Miniaturization: As devices shrink, connectors with pitches below 0.3mm are becoming more common, especially in wearables and IoT devices.
• High-Speed Data: Connectors supporting data rates above 25 Gbps are emerging to handle next-generation communication standards like 5G.
• Sustainability: Manufacturers are focusing on eco-friendly materials and designs that reduce waste during production and disposal.

Conclusion: Mastering Connector Selection for PCB Success

Understanding PCB connector types and following a solid connector selection guide are foundational to creating reliable and efficient printed circuit board designs. Whether you're working with board-to-board connectors for compact systems, wire-to-board connectors for power delivery, or RF connectors for high-frequency signals, each type has unique benefits and considerations. By carefully assessing electrical, mechanical, and environmental needs, you can choose connectors that enhance your project's performance and longevity.

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