Alternative to 4 pole 2,5mm Jack

[Twistx77]

Hi,

I'm working in a project where we have a device that needs a sensor that can be plug and unplugged using a cable. The problem is that I can't find suitable type of connectors to connect both devices and this is not the first time I end up in this situation. I usually use a 4 pole 2.5mm or 3.5mm but it has many things that I don't appreciate like it is usually limited to 4 poles, it is not pretty, it can be relatively big, etc. It has to be plugged and unplugged by the user so it can't be the typical molex connectors for PCBs.

I wonder if you guys know of any other options that are more suitable with most or all of this features:

1) 4 contacts or more.
2) Durable.
3) Possibility of being mounted in panel.
4) Small.
5) Pretty.

Any ideas?

Thank you.

[CM800]

What kind of class product is this?

Is this a high volume low cost or vice versa?

My suggestions:
http://uk.farnell.com/pro-signal/psg01593/plug-multipole-panel-4way/dp/1280759
http://uk.farnell.com/souriau/jbxer0g04fssdsr/socket-panel-0b-4-pole/dp/3218650
http://uk.farnell.com/binder/09-0320-00-05/socket-panel-5way/dp/1122819
http://uk.farnell.com/multicomp/2mt3002-w04300/socket-panel-front-mnt-5a-4-way/dp/1860763

[TheDirty]

I would agree, your requirements are a little broad.

For clips that are easy, cheap, inside use only, low voltage, and easily user handled, RJ-11, RJ-12, RJ-45 are good ones.  Just make sure they aren't mistaken for telephone/ethernet connectors.  Connectors are cheap and it's easy to find telephone/twisted wire cable in different lengths already.  I've seen RJ-11 connectors used as datalog and in field code update connectors quite often.

Looking back at your requirements, though, 4 pole 2.5mm, seems pretty small to me.  Not sure how much smaller you can get.

[mikeselectricstuff]

Take a look at M8 industrial connectors - reasonable range of poles and mounting options, and moulded plug cable assemblies readily available.
A bit bigger than jacks. Price varies hugely between manufacturers, the cheaper ones are pretty reasonable, especially if you need the IP rating.

For small & robust, there's not much out there as standard products at sensible prices - Fischer & Lemo will sell you some beautiful ones at extreme prices.

I doubt you'll find anything of a similar size+robustness to jacks though

[Kilrah]

Mini/micro USB connectors?
I'm the first to despise their misuse for unintended purposes on consumer gear, but we don't know the target group...

[Twistx77]

Thanks everyone.

I really liked this one http://uk.farnell.com/souriau/jbxer0g04fssdsr/socket-panel-0b-4-pole/dp/3218650

It could be for any equipment I just want to know different ones for any project but in this concrete case it is for a medical device for research. It doesn't have to be panel mounted but if it was a possibility would be better.

It can't be a cheap thing, since is a expensive device. Also I would rather prefer not to be anything that could be plugged buy mistake (USB, RJ-11, RJ-45) that's one of the reasons I don't like the jack. Right now I have based it in a 2,5mm jack soldered to a small board.

Maybe with that you can give me other solutions.

Thanks in advanced.

[mariush]

How about HiRose MQ172 ? It looks professional enough, it takes small space on the pcb, it's surface mount and rectangular... 5000 insertations rated, positive locking and doesn't look like other connectors  (well, maybe there's a hit of usb type c but it's different enough) :

http://uk.farnell.com/hirose-hrs/mq172x-4pa-66/connector-i-o-rcpt-4pos-smt/dp/2427874



And there's also the plugs  : http://uk.farnell.com/hirose-hrs/mq172x-4sa-cv-50/plug-i-o-4way/dp/1518739

[HAL-42b]

Pro audio Neutrik connectors, including MIDI connectors



or maybe industrial Ethernet connectors (not RJ45)



Both relatively common and hence cheap for the quality.

[Twistx77]

How about HiRose MQ172 ? It looks professional enough, it takes small space on the pcb, it's surface mount and rectangular... 5000 insertations rated, positive locking and doesn't look like other connectors  (well, maybe there's a hit of usb type c but it's different enough) :

http://uk.farnell.com/hirose-hrs/mq172x-4pa-66/connector-i-o-rcpt-4pos-smt/dp/2427874



And there's also the plugs  : http://uk.farnell.com/hirose-hrs/mq172x-4sa-cv-50/plug-i-o-4way/dp/1518739



I really like this one but it would be awesome something like that but with more contacts.

[Twistx77]

I finally found something that I like. It might be useful for someone else.



https://www.hirose.com/product/en/products/3200/

Also series 3100 and 3500 can be useful.

There are others for panel mount but they are more expensive

like series HR12. They are also round.

[Lomax]

I'll second the "M8" type connectors - while relatively pricey, they are a well established standard for industrial sensors and, at least here in Europe, widely available. Connections are secure, while remaining fairly small (8mm outer dia), and you can get them in up to four-pole configurations. Here are some reasonably cheap 4-pole ones I found on the bay. If you need more than four poles, I'd suggest the larger M12 type, which has up to eight positions.

I'd also like to add that I think it's a really bad idea to use connectors typically dedicated for one application for a completely different one. What will happen to your device if someone plugs a USB charger into a USB connector that expects a sensor? Or network equipment into what looks like an Ethernet port? I would even hesitate to use 2.5mm/3.5mm jacks for anything but audio applications; I've seen some manufacturers use these for power, making costly mistakes all too easy - keep in mind that the equipment you design may not always be used by ideal people in ideal situations... For example, I have a DJ mixer which takes 15V AC on a 3.5mm jack, easily mistaken for an audio lead when crawling around behind a stack of equipment in the dark, after a few beers Just imagine what that would do if plugged into a line input on a live PA system - not only to the equipment, but to the ears of the audience

[Twistx77]

I'll second the "M8" type connectors - while relatively pricey, they are a well established standard for industrial sensors, at least here in Europe, and widely available. Connections are secure, while remaining fairly small (8mm outer dia), and you can get them in up to four-pole configurations. Here are some reasonably cheap 4-pole ones I found on the bay. If you need more than four poles, I'd suggest the larger M12 type, which has up to eight positions.

I will take a better look at them.

Thank you.