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·
    2 days ago

    The fans themselves don’t need to be unplugged often, only the usb plug to the powerbank has a lot of cycles.

    The 3m friction tape is interesting, but tbh I think the simple 2.5mm headphone jack would be a bit easier to do and to replace in case it breaks and likely a tiny bit more reliable as I can buy it pre-done with built in stress relief against bending and it can also twist since it’s around to reduce any twisting related stress.

    The snaps look interesting for me but not for conducting electricity but for potentially holding the cables tightly in place. I see the brass/tin plated snaps a bit to be risky as they could potentially short out the powerbank when the fabric flexes which I really want to avoid. While I don’t have a cheapo powerbank, so it has short protection, I’d want to avoid testing that involuntarily. (At least I’m afraid it might do that) (Note, while the current which I use is low, the powerbank can deliver the standard 5v 2A, so a short could carry 2A in the worst case)

    The magnetic ones from rosenberg look interesting, but they are again quite large compared to the 2.5mm headphone jacks or even the 5.5mm 2.5mm barrel plugs.

    Also smol edit: Just re-read the part about “Sew in and when the suit is put on just snap them together”. The fans are not constantly unplugged and replugged after it’s assembled. The fans are only removed when doing a deeper clean of the fursuit head as otherwise they will simply stay in all the time. When putting on the suit head / desuiting, the powerbank is the one getting plugged to the step up module.

    Also here a better photo to illustrate how the entire thing is routed.

    • The white pouch at the bottom is where the power bank lives. (not installed rn)
    • The fans in the back are installed next and the cables get routed through the loops to the bottom of the head, where they get plugged into the step up module with the 4x RCY receptacles.
    • After the fans are plugged into the step up module, that then stays in there until the next deep cleaning. So the fans will not get unplugged for a long time but they do need to have the ability to get unplugged as they can’t be pulled through the cable loops.
    • When in use the step up module gets plugged in and unplugged from the powerbank

    I also plan to completely remove the step up module later as I found the exact same model of fans (same series of the same manufacturer) in a 5v version with the same specs. So when replacing the plugs I won’t need the step up module anymore.