Posted by Consolidated Electronic Team on | Comments Off on USB Cables 101 | A Guide to USB Connector Types
Initially developed in the 1990s as a standardized method of connecting computers with keyboards, displays, and other peripherals, Universal Serial Bus (USB) cables have transformed how electronic devices exchange power and data. USB simplifies and streamlines connections between a wide range of devices and is a necessary component of many tools we use daily.
Today, there are several USB connector types, each of which is further classified according to its power specifications. In this guide, we’ll discuss the most common types of USB connectors and the key selection considerations to help you identify the right product for your needs.
The Most Common USB Connector Types
Modern USB cables facilitate data communication and power delivery and are significantly faster than previous generations. However, they also come in multiple connection types, which are largely incompatible with one another. This makes it essential to identify the right USB type for your device’s port. Below, you can learn more about the different types of USB connectors.
USB A-Type
Widely regarded as the standard connector type, USB Type-A connectors are very common. They feature a flat, rectangular interface that joins directly to host devices, held in place using friction. A-Type connectors are durable enough to establish continuous connections but also user-friendly enough to be easily connected and disconnected. In most cases, IT peripherals have a USB Type-A connector that plugs into a PC. USB A-Type is also available in micro variations.
USB B-Type
USB Type-B connectors have traditionally been used with printer cables but are now more commonly used in cell phones and other peripheral devices like external hard drives. They feature a square interface and are available in several types:
Micro-USB B
USB Mini-b (5-pin)
USB Mini-b (4-pin)
USB Mini-B
Developed in the early 2000s, the USB mini-B features a slim profile and a snug fit. While it was initially used in early smartphones, digital cameras, and GPS navigation systems, it is less popular today due to the rise of micro USB technology.
USB Micro-B
As a very small 5-pin connector, the micro USB connector type is commonly used with small electronics like smartphones, game controllers, and power banks. USB micro-B is also widely used in Android smartphones that lack a USB-C receptacle.
USB C-Type
The newest type of connector, USB C-Type provides a one-size-fits-all solution for replacing older, larger USBs. It features a reversible, symmetrical interface and a sleek, slim design. It can also be adapted to support legacy connectors.
USB Revisions and Specifications
In addition to being categorized by type, USBs are further classified according to their power specifications. Each new version offers increased bandwidth and compatibility with an even broader range of devices and applications.
USB 1.1
While now obsolete, the USB 1.1 was the first widely used consumer USB. It enabled a maximum bandwidth of 12 Mpbs and was compatible with basic devices, like computer mice and keyboards.
USB 2.0
Also known as the high-speed USB, version 2.0 improved the bandwidth to 480 Mbps. This upgrade allows it to be used for higher bandwidth devices, such as transfer cables, adapters, and mass storage equipment. USB 2.0 also features backward compatibility with USB 1.1 devices.
USB 3.0 (aka USB 3.1 Gen 1)
Referred to as the SuperSpeed USB, 3.0 offers bandwidth improvements, jumping to a maximum of 4.8 Gbps. It also offers backward compatibility with legacy devices.
USB 3.1 (aka USB 3.1 Gen 2)
USB 3.1 can be identified by the switch to blue connectors. These products are capable of transfer speeds up to 5 Gbps and have been incorporated into products like the Apple MacBook.
USB 3.2
Updates have enabled these USB-C connectors to achieve 20 Gpbs.
USB 4.0 (aka USB4)
Initially launched in 2019 with a maximum data transfer rate of 40 Gbps, USB 4.0 connectors output a power of 100 watts. These USB-C cables feature the SuperSpeed logo, SS40, which stands for SuperSpeed 40 Gbps.
USB4 Version 2
The latest version of this specification, launched in 2022, features the highest-ever data transfer rate: 120 Gbps. Since this version is still very new, these USB-C cables may not be easily purchased yet.
USB Power Delivery Standards
With each USB advancement, devices achieve enhanced power delivery standards and improved communication capabilities.
USB 1.1
USB 2.0
USB 3.0
USB 3.1
Also Known As
USB 3.1 Gen 1
USB 3.1 Gen 2
Release Date
1998
2000
2008
2013
Speed/Transfer
Full Speed
High Speed
SuperSpeed
SuperSpeed
Rate
12 Mbit/s
480 Mbit/s
5 Gbit/s
10 Gbit/s
Power
N/A
5V, 1.8A
5V, 1.8A
20V, 5A
Max Cable Length
3 Meters (9’10”)
5 Meters (16’5”)
3 Meters (9’10”)
3 Meters (9’10”)
USB Type-C
As discussed earlier, newer developments in USBs offer a simple and comprehensive solution for data transfer and power supply for any device. A USB Type-C connector fits into one multi-use port to charge multiple devices simultaneously. It also offers backward compatibility to support previous USB standards (2.0, 3.0, and 3.1).
Type-C 3.1 features a reversible cable that enables two-way data and power transfer, along with 10 Gbps bandwidth and power up to 20 V at 5 Amps, or a total of 100 W. This is enough power to charge a laptop or operate a 4K monitor. Since this technology is nonproprietary, USB Type-C connectors are quickly becoming the new standard for many operating systems. For example, Intel’s Thunderbolt switched to USB Type-C ports while remaining compatible with USB 3.1. Apple MacBooks also now feature Type-C ports.
Important Considerations When Choosing a USB Cable
Selecting the right USB cable requires consideration of several factors, such as:
Cable length: If the cable length is too long, USB signals can deteriorate and significantly impact usability. However, the ideal length varies based on type.
Data transfer speed: USB cables must be able to deliver the transfer speeds needed to accomplish the tasks you’re performing. For example, USB 2.0 is fine for basic needs, but USB 3.0 and above is better for faster file transfer. Check your device’s data transfer capabilities and consider the cable’s frequency of use before deciding on a USB cable.
Durability: Cables that will be used frequently, such as charging cables, must be more durable than those only intended to be used occasionally. Durable cables usually have reinforced connectors and/or braided exteriors.
Certifications: USB cables can be tested according to USB-IF quality standards. Certified cables will offer a descriptive bandwidth and power rating.
Trusted manufacturer: Get USB cables from trusted manufacturers that can meet your data transfer and charging needs. Well-constructed USB connectors offer longer and more reliable service.
High-Quality USB Cables from Consolidated Electronic Wire & Cable
Consolidated Electronic Wire & Cable has over 100 years of experience delivering high-quality cable solutions. In addition to offering an extensive collection of standard USB connectors, we also create custom USB-C cables according to diverse data transfer and charging needs. Contact our team to learn more.
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Frequently Asked Questions (FAQ)
Below, you can explore some of the most common questions our team is asked about USB cables. If you’re looking for information not listed here, don’t hesitate to get in touch with us—we’re happy to help.
Posted by Consolidated Electronic Team on | Comments Off on How Are Cable Assemblies Overmolded?
Overmolding adds strength and resilience to a cable assembly so that it can withstand more extreme environments than it otherwise could. The cable overmolding process combines and seals a cable with a connector, resulting in a unified part that adds protection to its internal components.
Learn more about how cables are overmolded, the materials used during the manufacturing process, and the benefits of overmolded cable assemblies.
Cable Overmolding Materials
Common overmolding materials used in cable overmolding include:
PVC: Polyvinyl chloride or PVC is one of the most widely used thermoplastics for cable overmolding. PVC has a soft, rubber-like texture and high flexibility.
TPU: Thermoplastic polyurethane or TPU has a softer texture than PVC and comes in a wider array of colors. TPU is also more pliable and has a greater low-temperature flexibility, making it more stable amidst temperature changes.
Cable Overmolding Process
Overmolded assemblies are manufactured through injection molding, a manufacturing process that forces material into a mold cavity under pressure. The process starts when a storage area or hopper is filled with plastic resin, and an injection ram delivers the material into a barrel, where the plastic is heated to a liquid state.
Through a variety of methods, such as color compounding or master-batching, color is added to the resin. Inside the cavity, the material will cool and conform to the shape and design features of the mold, that may include logos, part numbers, and trade names.
Tamper-Proof Construction: Overmolding makes cable assemblies tamper-proof by encapsulating components. Unlike standard cables, overmolded cables have an extra layer of insulation that makes it harder for unauthorized personnel to interfere with or cut the cables.
Long Service Life: Overmolded cable assemblies are highly durable and long-lasting. They are protected from outside elements like extreme temperatures, abrasion, dust, water, dirt, debris, chemicals, and moisture, improving performance and enhancing cable assembly life.
Enhanced Cable Assembly Processes: Overmolding makes the assembly process more efficient and secure. This efficiency allows production costs to be reduced.
Shock and Vibration Resistance: With a robust housing and stable connections, overmolded cables can withstand shock and vibration without damage.
Flex and Strain Relief: By overmolding your cable assemblies, you can improve resistance to strain at the cable exit, where most of the stress between a cable and connector occurs. Cable overmolding also provides 360° strain relief and increased pull strength. The outer casing acts as a buffer between the inner wires of the cable and the external elements, protecting connector terminations and wires from damage over time.
Cable Management: Overmolded cable assemblies can have a soft, tactile feel when handled manually and make it possible for the cables to be easily managed.
Overmolded cable assemblies are no longer the rigid plastic they were decades ago. Overmolding materials are soft, tactile surfaces that are easy to handle and organize. They provide flexibility, strain resistance, durability, customizability, and strength to meet the most demanding cable applications. Overmolded cable assemblies are ideal for your custom design projects to enhance the protection of the assembly.
At Consolidated Electronic Wire & Cable, we provide custom overmolded cable assemblies for nearly any application. As an ISO 9001:2015 certified company, we are industry leaders in Total Quality Management (TQM) and are RoHS compliant. This ensures that our production process and customer service meet the highest quality standards. Contact us online or call us at 1-800-621-4278 for more information about our overmolding capabilities. To start your project, request a quote.
Cable assemblies enclose vulnerable wiring in protective sheaths and incorporate a nearly unlimited variety of connectors based on the intended use. Overmolded cable assemblies go a step beyond a simple sheath by enclosing the cable or wire and connector with overmolded material.
Cable or wire assemblies are placed within a mold, which is then injected with a pressurized molten plastic. Once the material hardens, it turns into a protective layer that seals the junction between the wires/cable and connectors to reduce the risk of damage.
Why Customize?
Customizing your overmolded cable assemblies is the best option for ensuring your electronics are protected. They are ultimately more rugged and cost-effective because the assemblies are seamless and essentially turned into just one comprehensive piece. The overmolding process allows customization of the following:
Overmold materials. Different materials imbue the assembly with different degrees of chemical or moisture resistance, heat resistance, and more. There are a variety of common plastics available for overmolding. Polyvinyl chloride (PVC) is an inexpensive general solution, but only offers minimal protection against strong acidic chemicals. Conversely, polyethylene (PE) and thermoplastic elastomer (TPE) can withstand strong acids. Polyurethane (PU) and thermoplastic polyurethane (TPU feature good resistance to weather, aging, and other harsh environmental conditions, making them ideal for outdoor applications. Material selection is based on degrees of protection desired and compatibility with wire insulation or jacket materials.
Color. During custom projects, manufacturers can add distinct colors and resins to the molten plastic. These colors can be used to match a company’s branding, color code the assembly according to instructions or regulations, or make the equipment more aesthetically pleasing. Custom colors can improve safety and organization, as well as increase the marketability of a product.
Environmental suitability. Overmolded assemblies can be built with unique features and molded layers to protect the wires against any extreme levels of wear, stress, and abrasion that may be expected in the intended operating environment.
Regulatory compliance. Some industries maintain specific regulations regarding required levels of protection for wiring and cable assemblies. Custom overmolding processes can be customized for compliance with a variety of quality standards including IPC/WHMA-A-620 and RoHS.
Customized Overmolded Cable Assembly Applications
Custom overmolded assemblies offer enhanced strain relief and suitability for a wide range of environments. They can outlast units with multiple separate parts or thin layers of protective sheathing. Custom colors also make them ideal for complex installations or environments where visibility is poor. We’re proud to serve the following industries:
Automotive.Automotive assemblies must withstand the harsh heated environments inside vehicles, exposure to dust, and contact with chemicals.
Communications. Communication wiring needs to be able to withstand harsh environmental conditions to ensure stable performance.
Home electronics. Wiring for consumers needs to be able to withstand a lot of flexing and adjustment and organizational coloring strategies make DIY installations and assemblies more appealing.
Medical equipment. Wiring for medical equipment and tools need to be able to withstand constant flexing and wear. They also need to be able to withstand continuous sanitation efforts to make them compliant with hygienic standards in hospitals.
Military and defense. Custom overmolded assemblies can withstand harsh conditions and extreme weather, use in a variety of different environments, and constant flexing. They offer an ideal solution for equipment which must operate reliably in harsh and dangerous environments in a variety of situations.
Oil and gas. Oil and gas industrial facilities, both in the processing plant and on the oil field, rely on cable assemblies for machinery and equipment that operate effectively near chemicals and constant wear and tear from harsh environmental factors.
Wind and solar energy. Alternative energy systems need robust wiring systems that remain durable in interior and exterior environments.
Industrial and OEM. Overmolded wire and cable assemblies are ideal for the harsh conditions found in industrial environments.
Consolidated Electronic Wire & Cable Solutions
When you choose custom overmolded cable assemblies, you get more than custom designs and colors. This process ensures you have a cable assembly that’s the right fit for the electronics, the environment, and the relevant regulatory standards of your operation. At Consolidated Electronic Wire & Cable Solutions, our team uses high-performance materials and expertly designed systems to create assemblies that outperform and outlast other assemblies.
Contact us today for more information about our overmolding capabilities.
At Consolidated Electronic Wire & Cable, we are committed to providing our customers with the resources they need to make an informed decision. On our website, we offer a variety of technical documents with information regarding NEMA configurations, color coding and insulation tips, and other wire and cable specific information.
Solid & Stranded AWG Chart: AWG-specification information for all outside diameter & wire types, including solid, concentric, rope bunched & more.
NEMA Configurations for Plugs & Receptacles: NEMA plug & receptacle configurations for voltage ranging from 125V to 600V, 15 to 60 amperes.
Color Coding Charts: Consolidated Electronic Wire & Cable’s color coding charts for various types of cable & wire products.
Wire Insulation Characteristics: A comparison of various types of wire insulation materials, including PVC, polyethylene, polypropylene, rubber, Neoprene, TPR & PEP.
NEMA Number Nomenclature: View the NEMA number nomenclature for plugs & receptacles, as well as current ratings & voltages.
Cable Standards Reference Guide: View the Cable Standards Reference Guide for NEC catalog reference information and a cable substitution chart.
We encourage you to visit the Technical Info area of our website to view these documents. We hope they prove to be of some use to you and that you find the information you are looking for.
Cabling is one of those components that people don’t often give much thought to, right? Need to power up something? Grab a cable, plug it in and go!
But, what if that cable poses risks to which you are unaware? Could the construction of that cabling system cause a weakness in the wiring?
The answers to these questions can be found in our new eBook, The Advantages of Molded Cable Assemblies. In this new resource, we provide you with information on how the protection of the terminal shells is an overlooked area that can be the difference between strong and weak cable assemblies.
Cable assemblies are highly engineered products made up of wiring, insulation, jacket, and terminals. As cable production and insulation has progressed over the years the safety of the wiring has improved tremendously. Intact cabling poses little risk of failure. The failures occur when the cables are cut and mated with a terminal. Choosing the right terminal end assembly is extremely important for all cable applications.
Terminal End and Cable Connectors
Let’s look more closely at terminal end options and the progression of cable connectors through the years. Realizing early on that joining exposed wires together was unsafe, the idea of a cable connector was born. Originally made out of porcelain or Bakelite, they were difficult to manufacture and expensive to replace.
Metal and plastic connectors prompted the replacement of these original multi-piece assemblies, and they became the standard until advancements in plastics and rubber forming led to molded cable connectors. These are the most commonly used connectors in today’s consumer electronics and appliances.
Because there are many options available for connecting spliced cables together, you need to have the most comprehensive information to understand how important it is to choose the right connector. In this eBook you will find explanations of:
Terminal shell options
Non-molded components
Molded cable assemblies
At Consolidated, we want you to be safe and your products protected. Choosing the right cable connector is vital for all of today’s complex cable systems. With almost 100 years of delivering power through cabling, we want to pass on our extensive experience and knowledge to you.
Visit our site today to download your free copy of The Advantages of Molded Cable Assemblies, and learn how Consolidated can provide you with the molded cable assembly needed for your project.
While most of the modern gadgets we rely on appear wireless, behind the scenes things like smart phones, Wi-Fi, and tablets, require miles of wires and cable to operate. When it comes to supplying the perfect cables and wires for the modern digitized and online landscape, one-size definitely does not fit all.
Whether you are working with business machines, medical equipment, automation systems, computers, or telecommunications, you need custom designed and custom-built cables. At Consolidated Electronic Wire & Cable, thanks to our Create Your Custom Cable Now form, and our latest eBook, Creating a Custom Cable, it has never been easier to create a custom cable to match your unique needs.
New Online Form: Create Your Custom Cable Now
When you embark on your next custom wire and cable project, the best place to start is on Consolidated’s user-friendly website. There you will find our Create Your Custom Cable Nowform. By completing this thorough but easy-to-navigate form, you are taking the first-step in our industry-leading custom cable production process. Other than general information, you will also be asked to supply details like:
Cable Type (Composite, Single or Multi Conductor, etc.)
Conductor (Number, AWG, Stranding)
Insulation Type
Shielding
Jacketing
Specification Demands
Once completed, just press the submit button. Soon after receiving your completed form, the experts at Consolidated will contact you directly. The best part of the form is that it gives us a solid idea about what you need, thus saving you both time and money.
In order to make filling out our Create Your Custom Cable Now even easier, we also offer a free eBook, Creating a Custom Cable to help guide you through the process.
New eBook: Creating a Custom Cable
Our new eBook, Creating a Custom Cable, gives customers an insider’s view of the design and production of custom cables. Some of the highlights of our eBook include:
Basic considerations such as cable length, cable size, environmental temperature, flexibility, and whether the cable will be used indoors or outdoors.
Deciding what kind of conductor is right for you, including bare, tinned, or silver plated copper wire.
Choosing a material to insulate your cables that will offer both performance and protection.
Other topics include shielding, jacketing, cable fillers, and critical standards.
If you are in the market for the highest quality custom cables, Consolidated Electronic Wire & Cable is your best choice. Both our Create Your Custom Cable Now form, and our eBook. Creating a Custom Cable, will help you start the process of creating the perfect custom cables to match both your specific application and your bottom line.
Custom-designed cable assemblies are an integral component of countless applications, including commercial and home electronics, appliances, medical equipment, aerospace, military, telecommunications, automotive, industrial equipment and more.
Designing a cable assembly can be difficult and challenging. Thankfully, a custom cable manufacturer can walk you through the process. However, be sure to address the items below with your manufacturer to ensure the final product meets your precise needs and exact application requirements:
Provide the manufacturer with full-scale drawings in a format that is well-recognized within the industry. If your drawing was created using unfamiliar software, the manufacturer may not be able to access the file and time will be wasted—which puts pertinent conversations about manufacturing and pricing on hold.
Schedule a design consultation with your manufacturer. They will have design experts on staff who can meet with you to ensure the job requirements are realistic and that your part can be successfully developed. For instance, discussing material options can be greatly beneficial, as design experts may know of a better, more suitable material for your part and application. Additionally, the right assistance can significantly reduce costs without affecting quality or performance.
Was your cable assembly designed and manufactured previously? Were you dissatisfied with the quality, timing or cost? If so, it is important that you communicate this to your wire and cable manufacturer. Understanding why the part or prior manufacturing process was deficient will make it easier to address and correct these matters.
Creating a custom cable assembly can be a challenging process, so don’t hesitate to ask a cable manufacturer for assistance. Through nearly a hundred years of service, Consolidated Electronic Wire & Cable has obtained extensive engineering expertise in custom cable assemblies for a wide range of applications.
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The answers to these questions can be found in our new eBook, 
Designing a cable assembly can be difficult and challenging. Thankfully, a custom cable manufacturer can walk you through the process. However, be sure to address the items below with your manufacturer to ensure the final product meets your precise needs and exact application requirements: