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.

  • lennyaa@pawb.socialOPEnglish
    1·
    4 days ago

    Thought about that as well, but sadly that’s not possible. I do have other locations to place the connector but those are only worse and have even more movement. Rn the connector is placed against some rigid foam where there is the least amount of movement but is somewhat influenced by the powerbank pouch. The only place I can move it, is to make the cable longer and place it at the bottom of the powerbank pouch where there is only soft faux fur which experiences a lot of movement during walking and turning the head.

    Smol edit: Just re-read the part about “disconnection due to movement”. –> The plug itself does stay connected. The wire at the crimped part ripped due to the stress of bending and the hard corner of the plastic casing of the RCY plug being pressed onto it. The plug itself does not get disconnected due to movement. I have only unplugged the plug in the photo to show the ripped cable better (the black wire of the negative side is ripped there).

    • Onno (VK6FLAB)@lemmy.radioEnglish
      2·
      4 days ago

      If it’s not breaking due to movement, but only due to strain, putting the joint at the power bank seems like the logical choice. You can use cable sheathing or heat shrink where the damage currently occurs as strain relief and abrasion protection.

      One other thing.

      You mention a pouch. Have you considered how to deal with your power bank if it suddenly self-ignites?

      • lennyaa@pawb.socialOPEnglish
        1·
        3 days ago

        About the power bank safety: The powerbank is easily accessible so I can rip it out if needed. In such a worst case scenario the first thing would be to remove the entire fursuit head first as that’s the fastest thing, before ripping out the power bank though and after removing the head when my irl head is safe is the time to think about what to do with the power bank.

        The suggestion about moving the joint to the power bank: Thing is, there are 4 fans, which I connect with a custom 4x Y splitter with a 5 to 12v step up converter to the USB port of the powerbank. The fans are removable but as they are hard to position you can basically consider them semi permanently mounted. The cables then go vertically down, where the 4 connectors all converge to the custom 5v usb to 12v RCY Y-splitter step up module where they get all plugged in. That 5 to 12v step up module then get’s plugged in to the powerbank. Each fan has to have it’s own connector as it’s not possible to solder inside the suit head and that’s the only way to loop all the wires through the small cable loops to then connect them all together at the Y splitter.

        In order to put the joint at the power bank, I’d have to somehow more or less attach a mount mechanism or something to the powerbank itself so that it holds the splitter module. The place where the powerbank is, is very very limited. When purchasing the power bank I specifically had to chose one which is very slim and as small as possible. So I can’t really put anything else where the powerbank is, so no mechanics to hold the cable joints there. I can basically only plug in a USB cable into the powerbank and that’s it.

        Also, I can’t add anything to the powerbank that makes it harder to remove, as after each use of the fursuit head, I have to remove the powerbank to recharge it (and later add it back) and I simply can’t fiddle with any complicated mechanisms after use. It has to be really quick, so essentially it can only be as much as unplugging a usb cable.

        To the heat shrinking: I have already tried that it does not work as it simply slips of the RCY plug.

        (sry if the comment is a bit chaotic, wrote it at night time)