DC Power Jack Sizes: A Comprehensive Guide To 5.5mm, 3.5mm, And More

Type	Outer Diameter (OD)	Inner Diameter (ID)	Common Applications
5.5mm x 2.1mm	5.5mm	2.1mm	Laptops, routers, CCTV cameras
5.5mm x 2.5mm	5.5mm	2.5mm	Industrial equipment, LED strips
3.5mm x 1.35mm	3.5mm	1.35mm	Small electronics, Arduino boards
4.0mm x 1.7mm	4.0mm	1.7mm	Portable devices, medical equipment
7.4mm x 5.0mm	7.4mm	5.0mm	High-power devices, amplifiers

Type

Outer Diameter (OD)

Inner Diameter (ID)

Common Applications

5.5mm x 2.1mm

5.5mm

2.1mm

Laptops, routers, CCTV cameras

5.5mm x 2.5mm

5.5mm

2.5mm

Industrial equipment, LED strips

3.5mm x 1.35mm

3.5mm

1.35mm

Small electronics, Arduino boards

4.0mm x 1.7mm

4.0mm

1.7mm

Portable devices, medical equipment

7.4mm x 5.0mm

7.4mm

5.0mm

High-power devices, amplifiers

Parameter	Details
Voltage Rating	Typically 3V to 48V DC (check device requirements).
Current Rating	Ranges from 0.5A to 10A+ (higher currents require thicker contacts).
Contact Material	Gold-plated (for low resistance) or nickel-plated (cost-effective).
Insulation Material	Plastic (PVC, nylon) or metal (for shielding).
IP Rating	Some jacks are IP67/IP68 waterproof for harsh environments.
Locking Mechanism	Some have screw-lock or latch designs to prevent accidental disconnection.

Parameter

Details

Voltage Rating

Typically 3V to 48V DC (check device requirements).

Current Rating

Ranges from 0.5A to 10A+ (higher currents require thicker contacts).

Contact Material

Gold-plated (for low resistance) or nickel-plated (cost-effective).

Insulation Material

Plastic (PVC, nylon) or metal (for shielding).

IP Rating

Some jacks are IP67/IP68 waterproof for harsh environments.

Locking Mechanism

Some have screw-lock or latch designs to prevent accidental disconnection.

Issue	Possible Cause	Solution
Loose Connection	Worn-out jack or mismatched plug size	Replace with a matching connector or use a locking jack.
Overheating	High current or poor contact	Use a higher-rated jack or check for corrosion.
Intermittent Power	Loose solder joints or damaged wiring	Resolder connections or replace the jack.
Polarity Mismatch	Incorrect wiring	Verify polarity with a multimeter before connecting.

Issue

Possible Cause

Solution

Loose Connection

Worn-out jack or mismatched plug size

Replace with a matching connector or use a locking jack.

Overheating

High current or poor contact

Use a higher-rated jack or check for corrosion.

Intermittent Power

Loose solder joints or damaged wiring

Resolder connections or replace the jack.

Polarity Mismatch

Incorrect wiring

Verify polarity with a multimeter before connecting.

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DC power jack

1. Common Types of DC Power Jacks

A. By Size (Barrel Dimensions)

B. By Mounting Style

C. By Polarity & Configuration

2. Key Specifications to Consider

3. Applications of DC Power Jacks

4. Common Issues & Solutions

5. Waterproof & Rugged DC Power Jacks

Example Products:

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