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DC power jack
A DC power jack is a connector used to supply direct current (DC) power to an electronic device. It comes in various sizes and pin configurations, the most common being a 2.1mm or 2.5mm inner diameter, and a 5.5mm outer diameter. The size and pin configuration may vary depending on the device's power requirements.
1. Common Types of DC Power Jacks
A. By Size (Barrel Dimensions)
| 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 |
B. By Mounting Style
- Panel Mount (for enclosures)
- PCB Mount (soldered directly to circuit boards)
- Wire Leads (for custom wiring)
C. By Polarity & Configuration
- Center Positive (+) – Common in consumer electronics.
- Center Negative (–) – Used in some automotive and industrial applications.
- Reversible (Switchable Polarity) – Some jacks allow polarity reversal.
2. Key Specifications to Consider
| 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. |
3. Applications of DC Power Jacks
- Consumer Electronics (laptops, routers, gaming consoles)
- Industrial Equipment (PLCs, motor controllers, sensors)
- Automotive & Marine (GPS devices, dash cams, boat electronics)
- Medical Devices (portable monitors, diagnostic tools)
- DIY & Prototyping (Arduino, Raspberry Pi, breadboard projects)
4. Common Issues & Solutions
| 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. |
5. Waterproof & Rugged DC Power Jacks
For harsh environments, consider:
- IP67/IP68-rated jacks (sealed against water and dust).
- Stainless steel or reinforced plastic housings for durability.
- Screw-lock or bayonet-style connectors for secure connections.
Example Products:
- CUI Devices PJ-002A (IP67 waterproof DC jack)
- Switchcraft 760K (Heavy-duty power connector)
- Amphenol PCD Series (High-reliability DC jacks)
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