In connector design and alternative selection, the "male / female" pairing relationship is crucial. The correct matching of the plug (male / pin / male end) with the socket (female end / socket / receptacle) not only requires a geometric size fit but also takes into account multiple dimensions such as elastic contacts, locking structure, and electrical contact stability. Many engineers, when looking for domestic alternatives or compatible parts, expect to have a plug / socket atlas (with structural sections, comparison tables, compatible models, etc.) for quick comparison and verification.
Based on Bourns, Inc.'s Modular Contacts series products, this article will share the ideas for building such a map and the key points for domestic adaptation.
Bourns Modular Contacts Overview (can be used as a composition reference)Bourns' Modular Contacts series products provide spring connectors in male/female/socket/receptacle forms (headers/receptacles) for various applications (board-to-board, board-to-device, board-to-battery, etc.).
They provide various pitch specifications: 70AA (2.54 mm), 70AB (1.27 mm), 70AD (4.00 mm) and so on, with both male and female terminal components available.
In terms of performance, these connectors from Bourns typically have a lifespan of 50,000 mating cycles; they also feature high-quality gold-plated contacts to maintain low resistance and reliable contact.
They also have some design features: symmetrical pad layout (for easy 180° rotation and insertion), end-to-end stacking capability, and automatic positioning characteristics, etc.
Bourns also provides design kits containing samples of various male and female connectors for developers to conduct prototype testing and compatibility verification.
The above information can be used as a reference blueprint for us to draw plug/socket diagrams.
Constructing the domestic connector plug/socket map: ideas and frameworkHere is a proposed framework and content module for display on the promotional website or for subsequent internal use:
Model Comparison Catalog + Quick Lookup Table
List a comparison table showing the Bourns original male and female terminal model numbers (e.g., "70AAJ-X / 70AAM-X / 70ADJ-X / 70AD-X / 70AB series"), marking the male and female terminals, contact number, spacing, arrangement direction, etc.
●For each corresponding entry, provide a recommended domestic equivalent model or compatible model (if available).
Structure section drawing / Disassembly view + Axonometric drawing
Sectional view of the plug and socket (transverse and longitudinal sections), indicating contact spring leaf, insulating structure, locking tab/locating pin, guide structure, etc.
● Combination of plug and socket, showing insertion depth, positioning surface contact pad, and protective shell structure.
●If possible, also show a disassembly perspective (the plug/socket disassembled into individual component units and numbered).
3. Key Dimensions and Tolerances Table
●For each pair of models, list key dimensions such as: pin spacing (pitch), insertion depth, tolerance, plug/male connector housing shape, auxiliary locating pin position and diameter, mold tolerance, etc.
● Mark dimension symbols on the graph (e.g., a, b, c, d, etc.).
4. Performance / Specification Comparison Table
●Original specification (Bourns) parameters: rated current, voltage, insertion/extraction life, contact resistance, temperature range, maximum insertion/pulling force, resistance to humidity and vibration, etc.
●If there is an existing domestic alternative component, you can compare the test data of the domestic component here and mark its advantages and disadvantages.
5. Compatibility / Alternative Suggestions + Risk Warnings
For each pair of plug/socket, provide 1-2 preferred domestic alternatives or design ideas, and indicate the potential differences and risks (such as contact gap deviation, insufficient spring rigidity, surface plating differences, lower insertion and removal life, etc.).
●Prompt the user to focus on which failure modes should be emphasized during design (such as poor contact at the contact points, jamming, misinsertion, etc.).
6. Failure/defect analysis illustration + optimization suggestions
●Show some typical fault scenarios (such as contact wear, oxidation corrosion, spring relaxation, and poor insertion and extraction) with analysis views, indicating possible structural weaknesses.
● Corresponding improvement suggestions (such as strengthening the contact spring pre-tension, optimizing the guide structure, adding dust protection design, etc.).
7. Graph Maintenance and Expansion
●Reserve slots for future model additions / derivative models.
Customer feedback channel: Involve customers / designers in the refinement of the map, upload the images and data they decompose or test.
Regular updates: Track the progress and performance improvements of domestic components and synchronize the update of the map content.
Displaying such图谱 on the company's independent website can not only reflect the technical strength but also enhance the trust and loyalty of industry users.
A clear, scalable, structured view with performance comparison of plug/socket adapter mapping, which has strong value in connector selection, domestic substitution, and project rapid response. Taking Bourns' Modular Contacts series as a reference, through disassembly analysis, CAD modeling, domestic substitution design, and comparative testing, it is possible to gradually build a mapping with industry reference significance. Displaying this mapping on an independent website not only showcases technical strength but also enhances customer trust and brand influence.
If you are interested in the domestic alternative products of Bourns brand connectors or have procurement needs, or if you have production or sales channels for this brand of connector alternatives, and wish to engage in in-depth cooperation or communication, please contact via the following contact information:
Manager Zhang (18665383950, same WeChat number)Contact us. We look forward to working with more industry partners to jointly build a high-quality connector ecosystem!
