Precision Box Header Connectors Manufacturer (1.27mm - 2.54mm Pitch)
Tonful Electric is a premier manufacturer of high-reliability Box Header Connectors (Shrouded Headers), engineered to provide secure, polarized Board-to-Board and Wire-to-Board connections. Designed primarily to mate perfectly with IDC (Insulation Displacement Contact) flat ribbon cable sockets, our box headers are available in industry-standard pitches including 1.27mm, 2.0mm, and 2.54mm.
Unlike standard bare pin headers, our box headers feature a protective plastic shroud with a central polarization keyway. This robust design prevents terminal bending during handling and completely eliminates the risk of reverse mating (anti-misinsertion). Manufactured with UL94 V-0 high-temperature plastics (PBT/LCP) and premium Gold/Tin plated brass contacts, Tonful delivers factory-direct pricing for industrial control, telecommunications, and automated measurement systems.
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Our Box Header Range
1.27mm Box Header
2.0mm Box Header
2.54mm Ejector Header
Box Header PH2.54mm Double Row 10*2Pin 90 Degree DIP
Box Header Dual Row PH2.54mm 2*7Pin 180 Degree SMT
Box Header Dual Row PH2.54mm 2*5Pin TH 180 Degree DIP
Technical Specifications: Box Header Connectors
| Specification | Available Options / Parameters |
|---|---|
| Pitch Sizes (间距尺寸) | 1.27mm, 2.0mm, 2.54mm |
| Number of Rows (排数配置) | Dual Row (Standard: 6 to 64 pins) |
| Mounting Orientation (安装方向) | Straight (180° Vertical), Right Angle (90° Horizontal), Surface Mount (SMT) |
| Contact Material (端子材质) | Brass (Standard), Phosphor Bronze (Optional) |
| Contact Plating (表面镀层) | Gold Flash, Selective Gold, Matte Tin, Bright Tin |
| Insulator Material (塑胶材质) | PBT, PA6T, PA9T, LCP (High-temp resistant for SMT reflow) |
| Polarization (防呆设计) | Center Keyway (Slot) for anti-misinsertion |
| Current Rating (额定电流) | 1.0A to 3.0A (Depending on pitch size) |
| Operating Temperature (工作温度) | -40°C to +105°C (Standard) / Up to +260°C (For LCP/SMT) |
| Mating Connector (配套连接器) | IDC Flat Cable Sockets / Ribbon Cable Connectors |
Why Choose TONFUL Box Header
Shrouded Protection & Anti-Misinsertion
The integrated plastic shroud ("box") fully protects the internal metal pins from being bent or damaged during assembly or transit. Furthermore, the built-in polarization keyway ensures the mating IDC socket can only be inserted in one correct orientation, preventing catastrophic reverse-polarity short circuits.
Premium Contact Plating
To ensure long-term signal integrity and corrosion resistance, we offer highly customizable plating options. Choose from Gold Flash or Selective Gold for high mating cycles, or Matte/Bright Tin for cost-effective static connections over our standard nickel underplate.
High-Temperature SMT Readiness
For automated Surface Mount Technology (SMT) assembly lines, our box headers utilize advanced plastics like LCP, PA6T, or PA9T. These insulators flawlessly withstand standard reflow soldering oven temperatures (up to 260°C) without blistering or warping.
Versatile Mounting Orientations
We provide complete layout flexibility for hardware engineers. Choose Straight (180°) for standard vertical stacking, Right-Angle (90°) for low-profile horizontal cable routing, or SMT with pick-and-place pads for high-density automated boards.
Automated Assembly Packaging
To maximize your manufacturing efficiency, all Tonful SMT box headers are supplied in professional Tape and Reel (T&R) packaging. We equip them with vacuum pick-up caps, ensuring zero downtime on your automated PCB pick-and-place lines.
The Perfect Wire-to-Board System
As a comprehensive manufacturer, Tonful doesn't just supply the PCB box header. We also manufacture the mating IDC (Insulation Displacement Contact) sockets and can supply fully assembled, custom flat ribbon cables, drastically simplifying your procurement process.
Professional Selection Guide
Step 1: Match the Pitch Size
The most critical dimension is the pitch (e.g., 1.27mm, 2.0mm, 2.54mm). This must match both your PCB footprint layout and the pitch of the mating IDC socket on your flat ribbon cable.
Step 2: Determine Pin Count
Calculate the total number of circuits required. Box headers are almost exclusively dual-row. Standard pin counts range from 6 pins (2x3) up to 64 pins (2x32), allowing for extensive signal routing.
Step 3: Choose the Mounting Orientation
Decide how the ribbon cable should exit the circuit board. Select Straight (180°) if the cable should go straight up, or Right-Angle (90°) if the cable needs to run flat and parallel to the board for tight enclosures.
Step 4: Select the Mounting Technology
Specify Through-Hole Technology (THT / DIP) for strong mechanical bonds in heavy-duty environments, or Surface Mount Technology (SMT / SMD) for automated, high-density circuitry.
Step 5: Specify the Contact Plating
Choose the contact finish based on your reliability needs. Gold plating is crucial for data signals requiring low contact resistance and frequent unplugging. Tin plating is a highly cost-effective solution for power connections.
Step 6: Confirm the Polarization Key
Standard box headers have one central polarization slot. However, for specific high-pin-count military or industrial applications, some headers require dual slots or no slots. Always verify the keyway matches your IDC socket.
Get Your Free Sample!
We provide samples for free, you just need to tell us what you need
MORE THAN JUST A BOX HEADER MANUFACTURER
Service Consultation
Whether your Box Header requirements are straightforward or complex, our team provides expert advice and technical consultation. For more intricate projects, we offer in-depth engineering support to ensure optimal product selection and application, guaranteeing safety and efficiency in your electrical systems.
Product Recommendations
Unsure which Box Header suits your system? Our specialists provide free, customized recommendations based on your specific operational and environmental requirements, ensuring you get the perfect fit for your electrical protection needs.
Installation Support
Need help with installation? Our technical team is available to answer your questions or provide hands-on support. For larger projects, we can even dispatch an engineer to your site for on-the-ground assistance, ensuring your Box Headers are installed correctly and function seamlessly within your electrical network.
Logistics Support
If you lack a reliable freight forwarder, we can arrange transportation from our factory to your project site at no extra cost. Our logistics team ensures timely and secure delivery to keep your project on schedule, minimizing downtime and delays.
Frequently Asked Questions
We have compiled some common questions from our clients. If your question isn’t included here, our customer service is always available to help. We’d love to talk with you.
Q1: What is the difference between a Box Header and an Ejector Header?
Both are shrouded headers designed for IDC sockets. A Box Header (简牛) is just the plastic box with a polarization slot. An Ejector Header (牛角) includes long locking latches (ejector levers) on the sides that lock the IDC socket in place and help push it out during removal.
Q2: Can I use a Box Header with standard female jumper wires?
Yes, absolutely. While they are optimized for IDC flat ribbon cable sockets, the internal pins are identical to standard pin headers. You can plug individual female Dupont/jumper wires into a box header without any issues.
Q3: Will the plastic housing melt during SMT reflow soldering?
Not if you select our SMT-specific box headers. We utilize high-temperature plastics like LCP or PA9T for our SMT lines, which easily withstand standard lead-free reflow oven temperatures (up to 260°C). Standard DIP connectors use PBT, optimized for wave soldering.
Q4: Do you offer Tape and Reel (T&R) packaging for automated assembly?
Yes. For all SMT box headers, we offer Tape and Reel packaging. We attach a high-temperature Kapton tape pad or a plastic pick-up cap to the top of the shroud so your automated SMT vacuum nozzles can easily pick and place the components.
Q5: What is the Minimum Order Quantity (MOQ) for custom box headers?
For standard sizes (like 2.54mm pitch with standard pin counts), we maintain a very low MOQ. For highly customized dimensions (specific gold plating thickness or non-standard plastic colors), the MOQ is evaluated based on production efficiency.
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