Barrel - Power Connectors

Part Number	Description / PDF	Quantity
PP-017 CUI Devices	CONN PWR PLUG 0.9X3.2MM SOLDER	4033
ADC-021-3-T/R Adam Tech	DC POWER JACK	660
50-00618 Tensility International Corporation	CONN PLUG 2.1MM MOLD STYLE	3444
ADP-1.3/3.5/9.5-SR Adam Tech	CONN PWR PLUG 1.3 X 3.5MM SOLDER	943
PJ-084AH CUI Devices	PWR JACK 2.0X5.9MM RT THROUGH HO	1135
PJ-038-SMT-TR CUI Devices	CONN PWR JACK 0.7X2.35MM SOLDER	27244
54-00256 Tensility International Corporation	CONN PWR JACK 2.5X5.5MM SHLD	2395
PJ-040DH CUI Devices	CONN PWR JACK 1.3X3.4MM SOLDER	4914
PJ-006A CUI Devices	CONN PWR JACK 2X5.5MM SOLDER	15035
PJ-018 CUI Devices	CONN PWR JACK 1.7X4MM SOLDER	6651
ADC-119-4-WP Adam Tech	DC POWER JACK, WATERPROOF	629
KLDX-PA-0202-B Kycon	POWER PLUG ASSEMBLY, 2.6 MM DIA,	1758
RASM712PX Switchcraft / Conxall	CONN PWR JACK 2.5X5.5MM SOLDER	7697
694106402002 Würth Elektronik Midcom	CONN PWR JACK 2.1X5.5MM SOLDER	2133
KLDPLX-0202-B Kycon	DC POWER JACK 2.5MM PNLMT SOLDER	4934
760HZ Switchcraft / Conxall	DC POWER PLUG, Z SERIES, 2.5MM X	0
PJ-202AH CUI Devices	CONN PWR JACK 2X5.5MM KINKED PIN	27401
PJ-002BH CUI Devices	CONN PWR JACK 2.5X5.5MM SOLDER	40291
PJ-040C CUI Devices	CONN PWR JACK 1X3.4MM SOLDER	0
PJ-082BH CUI Devices	CONN PWR JACK 2.5X5.5MM SOLDER	27715

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.