from lennyaa@pawb.social to askelectronics@discuss.tchncs.de on 16 Sep 2025 23:57
https://pawb.social/post/31648306
So far I have been using RCY connectors to connect some low power fans for a custom thingy (fursuit head, this will be relevant later (space limitations)). They have a fairly low power draw, so around 5v 0.1A.
This has worked for around a year, but as there is a lot of movement where I use it, the power leads have ripped right at the connector. It looks like this is caused by the lack of any strain relief as the connector is crimped and does not have the usual stress relief thingies, which are often seen at other stuff like psu cables, usb etc.
So I’m looking to upgrade / replace that with a different connector. I’m looking for one which has:
- stress relief against bending
- is twistable / unidirectional (so something more like a barrel jack / headphone jack)
- is small / slim (I have very limited room that’s why I initially used RCY). The size is mostly limited in thickness, not length.
- is able to carry the very low voltage and current of 5v 0.1-0.2A (so basically anything will do that)
- available in germany (most likely most things should be)
Things I have already considered:
- 5.5mm 2.5mm (/2.1mm) barrel type connector --> too thick sadly
- trying to protect the RCY plug with stuff like shrink tubes --> doesn’t work, just slips off
- thinner barrel type connectors --> can’t find a matching set of cable with plug and cable with receptacle
Rn my best bet seems to be 2.5mm headphone jacks. I do have the feeling that there might be something better out there, so that’s why I’m asking here.
Any help would be very appreciated. Thanks in advance!
Edit: Thanks for the suggestions so far, I forgot to add it to the list of the requirements that, the plug needs to be round, as one of the issues I had is that the 90° edges of the plug can get caught in the fabric. So I’m really looking for something round, so something without sharp hooks and release mechanisms.
threaded - newest