Brass PCB Connectors – Printed Circuit Board Connectors

Brass PCB Connectors – Printed Circuit Board Connectors | Electrical Accessories India

Brass PCB Connectors are precision-machined electrical interconnection components designed for reliable wire-to-board, board-to-board, and panel-to-board electrical connections in electronic assemblies, power electronics, industrial control systems, and instrumentation equipment. Electrical Accessories India manufactures a comprehensive range of brass PCB connectors including screw terminal PCB connectors, pluggable PCB connectors, barrier strip connectors, press-fit PCB connectors, and solder-type PCB terminals, all machined from certified brass to international material standards for global OEM supply.

Product Overview

What Are Brass PCB Connectors?

Brass PCB connectors are metallic contact elements – pins, sockets, screw terminals, or spring-clamp devices – mounted on or through a printed circuit board to interface with external wiring, other PCBs, or power buses. They provide the critical electro-mechanical interface between PCB-level circuitry and the wider electrical system. Common types include PCB screw terminal blocks, PCB barrier strips, right-angle PCB connectors, straight pin headers, SMT solder-tail connectors, press-fit through-hole connectors, and pluggable connector systems. Brass is the preferred contact material in higher-current PCB connectors due to its superior conductivity, machinability, solderability, and mechanical strength compared to phosphor bronze or beryllium copper in lower-frequency applications.

Construction and Pin Geometry

PCB connector bodies are precision CNC-turned or cold-formed from IS 319 / CuZn39Pb3 brass rod or strip material. Pin geometry includes straight square pins (0.6×0.6 mm, 0.8×0.8 mm, 1.0×1.0 mm), round pins (0.8–3.0 mm diameter), and press-fit compliant pins for zero-soldering assembly. Terminal screws are M2 to M5, with cage clamp or rising-cage designs for tool-free or tool-actuated termination. Pitch options cover 2.54 mm, 3.5 mm, 3.81 mm, 5.0 mm, 5.08 mm, 7.5 mm, and 10.16 mm for compatibility with standard PCB grid systems. Flanged bases ensure controlled solder joint geometry per IPC-A-610 Class 2 and Class 3 standards.

Electrical Characteristics

Brass PCB connectors deliver contact resistance below 5 mΩ at rated current, ensuring minimal power dissipation at PCB interfaces. Current ratings range from 3A (2.54 mm pitch, small signal) to 41A per pole (high-current 10.16 mm pitch, 10 mm² conductor). Voltage ratings up to 600V AC (UL recognition) and 1000V AC (IEC rated) are available. Dielectric withstand voltage ≥2500V AC (1 minute) per IEC 60947-7. Insulation resistance ≥100 MΩ at 500V DC per IEC 60068-2-6. The low-inductance pin geometry minimises switching transients in power electronics and switch-mode power supply (SMPS) designs.

Plating and Solderability

Solder-tail PCB connectors are supplied with tin-plated (Sn over Ni base) pins for RoHS-compliant lead-free soldering per IPC J-STD-001. Gold-plated contacts (Au 0.1–0.5 µm over Ni 1.27 µm) are available for low-contact-force signal connectors with ≥1 million insertion cycle life. Silver plating (3–5 µm) is offered for RF or high-frequency signal PCB connectors. Selective plating – gold on mating zone, tin on solder tail – is available for cost-optimised designs. All plating meets MIL-G-45204 (gold), ASTM B700 (silver), and IEC 60068-2-52 (salt spray) requirements.

Mechanical Durability

Brass PCB connector pins withstand solder reflow temperatures up to 260°C (JEDEC J-STD-020 MSL compliant). Contact retention force meets IEC 60352-2 requirements. Mating connectors are rated for 200–1000 insertion/extraction cycles depending on contact plating and design. PCB solder joints comply with IPC-A-610 Class 2 and 3 inspection criteria. Vibration resistance per IEC 60068-2-6 (10–2000 Hz, 20G) is verified for industrial and automotive applications. Push-in spring-clamp variants are torque-free, eliminating screw fatigue issues in high-vibration environments.

Insulator Housing Options

Connector housings are available in PA6, PA66 (GF30), LCP (liquid crystal polymer), PBT, and PPS materials for operating temperatures from −40°C to +150°C. UL94 V-0 flammability rating is standard across all housing materials. Colour coding (grey, blue, green, black, red) for polarity identification and circuit segregation is available. Housing pitch tolerance ±0.05 mm ensures consistent PCB land pattern alignment. Snap-in retention clips, locking levers, and panel-mount flanges are available for connector system stability in vibrating environments.

PCB Mounting and Assembly Compatibility

Brass PCB connectors are available in through-hole (THT), surface mount (SMT), press-fit, and hybrid configurations. THT connectors suit wave soldering and hand soldering assembly; SMT variants are compatible with reflow oven assembly lines (SAC305 lead-free solder). Press-fit connectors are compatible with FR4, high-Tg FR4, and ceramic PCB substrates, requiring controlled press forces of 50–200N per pin for compliant zone installation. PCB land pattern data, 3D CAD models (STEP format), and application notes are provided with each product family.

Key Features

• Precision CNC-machined / cold-formed from IS 319 / CuZn39Pb3 brass
• Pitch range: 2.54 mm to 10.16 mm (standard PCB grids)
• Current rating: 3A to 41A per pole
• Voltage rating: up to 1000V AC (IEC) / 600V AC (UL)
• Contact resistance: < 5 mΩ at rated current
• Plating: Sn, Ni, Au, Ag – RoHS compliant lead-free options
• Housing: PA66/LCP/PBT, UL94 V-0 rated, −40°C to +150°C
• Mounting: THT, SMT, press-fit, pluggable, and panel-mount
• Compliant with IEC 60947-7, UL 508, IPC-A-610 Class 2/3

Versatile Pitch and Pole Count

Brass PCB connectors are available in 1-pole to 24-pole configurations, accommodating single-channel sensors, multi-phase motor drives, power inverter PCBs, and communication gateway boards. Standard pitches (2.54 mm, 3.5 mm, 5.08 mm) ensure footprint compatibility with Phoenix Contact MKDS, Wago 2060, Molex 39500, and TE Connectivity MSTB equivalent connector series. Custom pitch, pole count, and pin length combinations are produced per OEM-specific PCB layouts.

High Current-Density Design

For power electronics PCBs (motor drives, battery management systems, EV chargers, solar inverters), high-current brass PCB connectors rated 25A–41A per pole with 10 mm² conductor capacity are available. Integral heat-spreader flanges, twin-screw clamping, and silver-plated contacts reduce junction temperature rise under sustained load. These connectors meet IEC 61010-1 (measuring and control equipment) and IEC 62368-1 (audio/video equipment) creepage and clearance requirements for 600V pollution degree 2 environments.

Pluggable Connector Systems

Pluggable brass PCB connector systems consist of a PCB-mounted header (male) and a field-wiring plug (female), enabling complete subassembly withdrawal for maintenance without de-soldering. Locking mechanisms include: screwless push-lock latches, integral threaded lock screws, and bayonet locking. Plug and header are keyed by offset pin positions, colour, and mechanical polarisation features to prevent mis-mating. Pluggable systems reduce production test time and facilitate PCB replacement in the field without conductor re-termination.

Compliance with International PCB Assembly Standards

Products are designed to meet IEC 60068-2 environmental test standards (temperature cycling, humidity, vibration, shock), IPC-A-610 workmanship standards, and JEDEC soldering standards. Automotive-grade variants comply with AEC-Q200 passive component qualification and USCAR-2 connector reliability requirements. Military-grade brass PCB connectors meet MIL-C-5015, MIL-DTL-38999 series III dimensional and performance requirements on request.

RoHS, REACH, and Conflict Minerals Compliance

All brass PCB connectors are manufactured and plated without restricted substances per RoHS Directive 2011/65/EU (Pb, Cd, Hg, Cr⁶⁺, PBB, PBDE below threshold limits). REACH SVHC declaration and conflict minerals (Dodd-Frank Section 1502) reporting documentation are available. Halogen-free housing variants (IEC 61249-2-21) are available for PCBA assemblies requiring flame retardancy without brominated or chlorinated compounds.

Export Approvals and Global Standards

Products meet IEC 60947-7-1 (terminal blocks for copper conductors), IEC 60352-2 (solderless connections), UL 508 (industrial control equipment), and CE marking requirements under the Low Voltage Directive (2014/35/EU). SASO, BIS, and other market-specific certifications are available on request. Products are exported to the EU, North America, Middle East, Southeast Asia, and Australia through established distribution channels.

Technical Specifications

Raw Material Grades – International Equivalents

Product Types and Variants

• PCB Screw Terminal Blocks – Single/double row, pitch 3.5–10.16 mm, screw clamp
• Pluggable PCB Connectors – Separable plug + header; maintenance-friendly design
• PCB Barrier Strip Connectors – High-current rated, dual-row, nickel-plated
• Right-Angle PCB Connectors – 90° pin orientation for panel-edge wiring access
• PCB Press-Fit Connectors – Zero-solder installation; automotive/industrial grade
• SMT PCB Terminal Blocks – Reflow-solderable, 2.54–5.08 mm pitch
• Push-In Spring Clamp PCB Connectors – Tool-free, vibration-resistant clamping
• High-Current PCB Power Connectors – Up to 41A/pole, 10 mm² conductor

Applications

• Industrial Automation: PLC I/O module connectors, fieldbus interface PCBs, motion control drives
• Power Electronics: SMPS boards, motor drive PCBs, inverter gate driver connections
• Energy Systems: Solar microinverter PCBs, battery management system (BMS) connectors
• Instrumentation: Measurement modules, data acquisition cards, signal conditioning PCBs
• Telecommunications: Base station power supply PCBs, router power modules
• Medical Electronics: Diagnostic equipment PCBs, patient monitoring system boards
• Automotive Electronics: ECU power supply PCBs, DC-DC converter boards, EV chargers
• Building Automation: BMS controller PCBs, HVAC control boards, smart meter modules

Manufacturing Process

Brass PCB connector pins and contacts are produced via CNC Swiss-type turning (for high-precision small-diameter pins) and multi-slide cold forming (for high-volume flat terminals). Starting material is IS 319 / CuZn39Pb3 brass rod or strip, verified for chemical composition and conductivity on receipt. Turning centres produce pin diameters with tolerances of ±0.01 mm and surface finish Ra ≤ 0.8 µm for consistent solder wetting. Formed contacts undergo progressive die stamping for flanges, retention barbs, and spring features. After machining or forming, parts are barrel or rack plated: copper strike (2–3 µm), nickel undercoat (2–5 µm), and tin or gold topcoat. Plated parts are gauged for thickness by XRF, inspected for solderability per IEC 60068-2-54, and co-inserted into plastic housings on automated assembly equipment. Final inspection includes contact resistance measurement, insertion/extraction force test, and visual inspection per AQL 1.5 Level II sampling.

Quality Standards and Certifications

• Material: IS 319 / EN 12164 – Mill test certificates with each lot
• Electrical: IEC 60947-7-1 (terminal blocks), IEC 60352-2 (solderless connections)
• Solderability: IEC 60068-2-54, IPC J-STD-002
• PCB assembly: IPC-A-610 Class 2/3 soldering workmanship
• Environmental: IEC 60068-2 (temperature, humidity, vibration, salt spray)
• Flammability: UL94 V-0 housing material
• RoHS: EU Directive 2011/65/EU – Lab test reports available
• ISO 9001:2015 – Certified quality management system

Why Choose Electrical Accessories India

Electrical Accessories India is a vertically integrated manufacturer of brass PCB connectors, machining and plating all products in-house. Unlike trading companies, we control every stage from billet to finished connector – ensuring quality, traceability, and lead time commitments. Our engineering team supports OEM customers from initial footprint design through prototype validation and production scale-up. We maintain AQL-controlled inspection with documented inspection records per ISO 9001. Export experience spanning 40+ countries ensures compliance documentation for all major markets. Custom connector designs are developed under NDA, with tooling investment amortised over agreed production volumes.

Pricing

Indicative Export Price: US$ 11.50 per kilogram (FOB Indian Port)
Applicable to standard brass PCB connectors – natural brass or tin-plated finish, bulk packed.
Gold-plated contacts, custom housings, and small-quantity prototype orders are priced separately. Contact us for a volume-based quotation.

Frequently Asked Questions

Q1: What pitch PCB connectors do you manufacture?

We manufacture PCB connectors in standard pitches: 2.54 mm, 3.5 mm, 3.81 mm, 5.0 mm, 5.08 mm, 7.5 mm, and 10.16 mm. Custom pitches to suit proprietary PCB layouts are available for OEM orders with minimum quantities from 5,000 pieces per variant.

Q2: Are your brass PCB connectors compatible with lead-free solder processes?

Yes. All solder-tail PCB connectors are supplied with tin-over-nickel plating (RoHS compliant, lead-free). Pin metallurgy and housing materials are qualified for SAC305 reflow profiles (peak 260°C) and wave soldering processes. Full JEDEC MSL rating documentation is available for SMT connectors.

Q3: Can you provide 3D CAD models and PCB footprints?

Yes. STEP 3D models and IPC-7351 compliant PCB land pattern data are available for standard catalogue products. For custom designs, we provide full mechanical drawings (DXF/PDF) and recommended PCB footprints within 5 working days of design confirmation.

Q4: What is the difference between a THT and SMT PCB connector?

Through-hole (THT) connectors have pins inserted through PCB holes and soldered on the reverse side – providing strong mechanical anchoring and compatibility with wave soldering. Surface mount (SMT) connectors have solder pads that reflow onto PCB copper pads – suitable for double-sided automated assembly but with lower mechanical retention than THT. For power connectors subject to cable pull forces, THT or press-fit mounting is recommended.

Q5: What current rating is available for high-power PCB connectors?

High-current brass PCB connectors rated 25A to 41A per pole are available in 5.08 mm and 10.16 mm pitches. For higher currents (above 41A per pole), we recommend copper PCB busbar connectors or ring-lug style bolted connections rather than screw-terminal PCB connectors, to avoid PCB copper trace heating at connector interfaces.

Q6: Are gold-plated PCB connector pins available?

Yes. Gold plating (0.1 µm selective flash to 0.5 µm full gold) over nickel undercoat is available for low-contact-force signal PCB connectors requiring high reliability and extended insertion cycle life (≥1 million cycles). Gold plating is typically specified for test socket connectors, hot-plug modules, and high-reliability industrial connectors.

Q7: Do you supply PCB connectors for automotive applications?

Yes. Automotive-grade brass PCB connectors complying with AEC-Q200 qualification, USCAR-2 connector reliability, and ISO 16750 environmental requirements are available. Applications include EV onboard charger PCBs, battery management system modules, and ADAS sensor power supply boards.

Q8: What is the minimum order quantity for custom PCB connectors?

For standard catalogue variants, there is no minimum order for sample quantities (1–100 pieces for prototyping). Production orders start from 500 pieces per part number. Custom tooled variants require 5,000–10,000 pieces MOQ depending on complexity, with tooling cost amortised into unit pricing over the agreed production volume.

Q9: What certifications come with PCB connector products?

Standard documentation includes: material test certificate, dimensional inspection report, RoHS compliance certificate, REACH declaration, solderability test report, and country of origin certificate. UL recognition, CE declaration, and customer-specific qualification reports are available on request.

Q10: How do I select the correct PCB connector for my power supply board?

Key selection parameters are: (1) conductor cross-section and current rating, (2) PCB pitch and footprint constraints, (3) voltage class and creepage/clearance requirements, (4) assembly method (THT/SMT/press-fit), (5) field wiring method (screw/spring-clamp/pluggable), and (6) environmental class (temperature, humidity, vibration). Our technical team provides connector selection support based on your PCB specification and application requirements.

Equivalent Terms in Other Languages

Related Products and Linked Terms

Brass Tunnel Connectors | Copper Cable Connectors | Brass Terminal Blocks | PCB Screw Terminals | DIN Rail Terminal Strips | Brass Pin Headers | SMT Power Connectors | PCB Barrier Strips | Pluggable Terminal Blocks | Brass Machined Contacts | PCB Spring Clamp Connectors | Copper Grounding Ferrule Connectors | Brass Panel Connectors | Press-Fit PCB Contacts | Brass Board Connectors

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Electrical Accessories India supplies brass PCB connectors to electronics OEMs, EMS companies, power electronics manufacturers, and industrial automation integrators worldwide. For samples, technical drawings, or volume pricing, contact our export sales team.

Email: info@elecaccs.com | Website: www.elecaccs.com

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