Barrel - Power Connectors

Part Number	Description / PDF	Quantity
PP3-013 CUI Devices	POWER PLUG, 1.7 X 4.0 X 9.5 MM,	508
50-00001 Tensility International Corporation	CONN PWR PLUG 1.1X3.5MM SOLDER	6542
54-00138 Tensility International Corporation	CONN JACK R/A PCB 2.35X0.7MM	0
PCL722A Switchcraft / Conxall	CONN POWER JACK SOLDER EYELET	1285
KLDHCX-8-0202-B Kycon	CONN PWR JACK 2.5X5.5MM SOLDER	3801
50-00011 Tensility International Corporation	CONN PLUG 5.5X2.5MM LOCK STYLE	4499
PJ-031CH CUI Devices	CONN PWR JACK 1X3.4MM SOLDER	19828
PJ-044A CUI Devices	CONN PWR JACK 2X5.5MM SOLDER	10635
PJ-041H CUI Devices	CONN PWR JACK 1.75X4.75MM SOLDER	4617
712AH Switchcraft / Conxall	JACK, 2.5MM PIN, SHORT BUSHING,	129
PC721A Switchcraft / Conxall	POWER JAX	1190
694108106102 Würth Elektronik Midcom	CONN PWR JACK 2.5X5.5MM SOLDER	1000
RAPC722X Switchcraft / Conxall	CONN PWR JACK 2X5.5MM SOLDER	38159
3643 Adafruit	2.1MM DC POWER JACK WITH ROCKER	0
PJ-005B CUI Devices	CONN PWR JACK 2.5X5.5MM SOLDER	47307
PJ-032B CUI Devices	CONN PWR JACK 2.5X5.5MM SOLDER	2341
L721A Switchcraft / Conxall	LONGER BUSHING D-FLA	2355
S761KS12 Switchcraft / Conxall	CONN PWR PLUG 2X5.5MM SOLDER	1376
PJ-046 CUI Devices	CON PWR JCK 1.65 X 5.15MM VERT	400
721A Switchcraft / Conxall	POWER JACK 2.1MM PI	6933

Barrel - Power Connectors

1. Overview

Barrel power connectors are cylindrical electrical connectors designed for DC power transmission. Featuring a coaxial design with a central pin and outer sleeve, these connectors provide reliable power delivery for devices requiring voltages typically below 20V. Their standardized dimensions and polarized design prevent accidental reverse polarity connections. Widely adopted in consumer electronics, industrial equipment, and medical devices, barrel connectors offer a balance of cost-efficiency and durability in power delivery systems.

2. Main Types and Functional Classification

Type	Functional Characteristics	Application Examples
Standard Barrel	5.5mm outer diameter, 2.1mm inner diameter	Laptop adapters, industrial machinery
Mini Barrel	3.5mm outer diameter, 1.35mm inner diameter	Portable audio devices, routers
Micro Barrel	2.5mm outer diameter, 0.7mm inner diameter	Wearable devices, IoT sensors
Latching Barrel	Mechanical lock with threaded coupling	Medical equipment, aerospace systems
High-Current Barrel	Gold-plated contacts for >5A applications	3D printers, industrial robotics

3. Structure and Components

Typical barrel connector construction includes:

Center Conductor: Brass or phosphor bronze with gold plating (0.1-0.5 m) for optimal conductivity
Insulation Layer: High-temperature resistant thermoplastic (UL94 V-0 rated) separating inner/outer contacts
Outer Sleeve: Spring-loaded phosphor bronze with tin plating for 360 electrical contact
Housing: Flame-retardant PBT or LCP polymer (operating temp: -40 C to +125 C)
Cable Termination: Solder or crimp contacts with strain relief boots (10-15N pull force rating)

4. Key Technical Specifications

Parameter	Value Range	Importance
Voltage Rating	6V-30V DC	Determines maximum power capacity
Current Rating	0.5A-10A	Defines thermal performance limits
Contact Resistance	<5m	Impacts power efficiency and heating
Insulation Resistance	>100M	Ensures electrical safety
Operating Temperature	-40 C to +105 C	Dictates environmental suitability
Insertion Force	0.5N-5N	Affects user experience and durability
Durability	1,000-10,000 cycles	Directly impacts product lifespan

5. Application Areas

Primary deployment sectors include:

Consumer Electronics: Notebook power supplies, game consoles, home routers
Industrial Equipment: CNC machines, automated test systems, factory sensors
Medical Devices: Portable diagnostic equipment, patient monitors, infusion pumps
Telecom Infrastructure: Outdoor wireless access points, fiber optic transceivers
Renewable Energy: Solar charge controllers, energy storage systems

6. Leading Manufacturers and Products

Manufacturer	Representative Product	Key Features
Molex	47050 Series	8A rating, 10,000 mating cycles, RoHS compliant
TE Connectivity	POWR-BLADE	Modular design, 12V/5A capacity, automotive qualified
Amphenol	DSMB Series	IP67 rated, vibration-resistant, -55 C to +125 C range
JAE Electronics	DT2 Series	0.3mm pitch, EMI shielding, 5G network equipment
ITT Cannon	C-Series	Military-spec, quick-mate design, 20kV dielectric strength

7. Selection Recommendations

Key consideration factors:

Power Requirements: Calculate VA rating considering inrush current (typically 2-3 steady-state)
Environmental Conditions: Select IP rating based on exposure to moisture/dust (IP20 for indoor, IP67 for outdoor)
Space Constraints: Micro-barrel connectors save 60% PCB area vs standard types
Compliance Standards: Ensure UL/CSA/IEC certifications for medical/industrial applications
Total Cost: Evaluate lifetime cost including replacement frequency and maintenance

Case Study: When designing a 12V/3A industrial camera system, select connectors with minimum 5A rating (20% derating), IP65 housing, and 5000+ mating cycles for maintenance-free operation over 5-year lifespan.

8. Industry Trend Analysis

Key development directions:

Miniaturization: 0.8mm micro-barrel connectors enabling wearable device charging
High-Power Density: Innovations in contact materials (graphene-coated Cu) for 15A+ capacity
Smart Integration: Connectors with built-in current sensing and overvoltage protection
Environmental Compliance: Halogen-free materials and 100% recyclable polymer housings
Standardization: Global adoption of IEC 60130-10 for cross-manufacturer compatibility

The market is projected to grow at 6.2% CAGR (2023-2030) driven by EV charging stations, 5G infrastructure, and portable medical device demand.