54-00401 Rugged DC Power Connectors with High-Temp LCP/Nylon Insulation
Tensility DC power connectors are designed for reliable, efficient power delivery in demanding applications. Supporting up to 9 A at 48 VDC depending on the configuration, these connectors are built for performance in environments where thermal resistance, mechanical durability, and ingress protection are critical. The product lineup includes variants with internal insulation made of high-performance liquid crystal polymer (LCP) as well as robust nylon, providing options that meet a wide range of thermal and environmental demands. LCP versions are rated for continuous operation between -50°C and +200°C, making them ideal for high-heat installations such as power supplies, motors, or other components that generate sustained heat.
LCP-insulated DC connectors provide high heat resistance, maintaining stability and strength up to +200°C. They also resist deformation under thermal load, making them suitable for high-temperature or continuous-use power systems. Nylon has a naturally high tensile strength and molecular flexibility, allowing it to absorb mechanical shock without cracking or deforming. This allows nylon insulation to be impact-resistant, making it especially useful in connectors exposed to vibration, handling, or frequent mating cycles.
The product lineup includes plugs and panel-mount jacks with pre-attached leads. Panel-mount jacks and their cable assembly counterparts feature threaded housings for secure installation and offer IP67-rated sealing when mated, protecting against dust and water ingress in wet or outdoor environments. Gold-plated contacts provide long-term conductivity and corrosion resistance, while compatibility with 5.5 mm OD barrel-style plugs allows easy integration into standard DC power designs.
Features:
- All connector types utilize high-performance insulation made from either LCP or nylon, offering both high-temperature stability and rugged durability
- LCP variants operate within a wide temperature range from -50°C to +200°C, ideal for high-heat environments and demanding applications
- Panel-mount connectors and cable assemblies feature IP67 sealing when mated, offering protection from dust and water exposure
- Threaded panel-mount designs provide secure, vibration-resistant installation for long-term performance
- Standard 5.5 mm x 2.1 mm and 5.5 mm x 2.5 mm plug/jack sizes ensure compatibility with widely used DC barrel connections
- Gold-plated contacts enhance electrical conductivity and resist corrosion over time
- Available in plug, panel-mount jack, and panel-mount to lead cable assembly formats for integration flexibility
Applications:
- Robotics
- Test and measurement
- Medical
- Communications
- LED lighting
- Wearables
- Government and defense
- Aerospace
- Power supplies
- Labs and bench testing
- High-security systems
- Prototyping and development
