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Rectangular connectors - headers, male pins - are widely used in a variety of applications for securely fastening two components together.

A typical rectangular connector consists of an array of metal contact pins that have been inserted into a plastic housing composed of a pair of side walls, a top wall, and a set of technical lances. The metal contacts are typically made from copper, brass, or stainless steel and are then plated with a surface finish such as tin, nickel, or gold. These components enable the connector to sustain a given electrical current while the plastic housing and lances provide the necessary mechanical stability and create an airtight seal around the pins. If the application requires, the side walls may also feature unique molded "clocks" to help prevent misalignment during assembly.

Depending on the needs of the device or equipment being manufactured, a rectangular connector can be designed to satisfy a range of applications. Commonly, the connector will include several rows of male pins, which are typically 6.3mm (.25") or 2.54mm (.1") apart. Some offer up to 200 pins in a single row. The number of contact pins for a given rectangular connector can be determined by the number of contacts that are desired, the overall dimensions of the unit, and the application’s current-carrying requirements.

Rectangular connectors are most often used in electronic devices such as computers, telephones, radios, and other consumer electronics. Many of these devices also require female pins so that the male pins of the connector can be firmly held in place. Female pins are typically made from plastic, and they have an internal contact that can be pushed into the male pins for a secure connection.

Another common application of rectangular connectors are in electrical power cables. In this setting, male pins are inserted into the ends of the cable, and the female pins of the connector are held in place to allow a secure electrical connection to be made. Rectangular connectors can also be used to join automotive and other light-duty wires used in various vehicles and equipment.

The working principle of rectangular connectors is simple, yet effective. The arrangement of rows of male pins enables them to securely hold the female pins in place, while the plastic housing and lances provide the necessary airtight seal around the pins to maintain an even and reliable electrical connection. Depending on the design and the application requirements, the pins may also be plated with a surface finish such as tin, nickel, or gold, to enhance their performance.

The design of a rectangular connector also ensures that the female pins fit securely and that the device is always correctly assembled. This helps to prevent undesired contact between the male and female pins that could result in incorrect operating conditions. Furthermore, depending on the application, the connector may also feature molded "clocks," which ensure that misalignment during assembly does not occur.

In summary, rectangular connectors - headers, male pins - are used in a variety of applications to securely attach two components together. The metal contacts of the connector are designed to sustain a given electrical current, while the plastic housing and lances provide the necessary mechanical stability and airtight seal around the pins. Depending on the needs of the device or equipment being manufactured, the connector can be designed to meet a wide range of performance and reliability requirements.

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