Coaxial power connector

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(Redirected from Coaxial DC Power Connectors)

Common DC power connectors
A coaxial power connector is a miniature power connector used for attaching extra-low voltage devices such as consumer electronics to external electricity. Also known as barrel connectors, concentric barrel connectors or tip connectors, these small cylindrical connectors come in an enormous variety of sizes.
The primary use of these plugs is a DC connector (or sometimes AC) on the cable connected to a power supply. The matching jack or socket is then mounted in the equipment to be powered. Some of these jacks contain a normally closed switch; the switch can disconnect internal batteries whenever the power supply is connected to avoid the risk of battery leakage or explosion posed by incorrect recharging of the batteries.
Contents
1 Connector Construction
2 Many Different Sizes
3 Standards
4 Universal Power Supplies
5 Generic types
6 EIAJ standards
7 DIN 45323 Power Connectors
8 Guidelines for selection
9 RadioShack Adaptaplug Conversion Matrix
10 References
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Connector Construction
Some power plugs are merely subminature phone plugs pressed into service as power connectors. The two connectors on the left of the picture above are subminature and miniature phone plugs respectively, the subminiature size being 3/32 inch and the miniature being 1/8 inch. The original application of these connectors was for audio microphones and headsets. These connectors are typically 1/8 inch, 3/32 inch, 3.5 mm, or 2.5 mm in diameter. The original telephone plug was 1/4 inch in diameter. These connectors were not designed to carry power, and there is a possibility of shorting the power supply when mating the connector.
Some connectors have been specially designed as power connectors.
Cylindrical plugs generally have an insulated tip constructed to accept insertion of a pin (but note also the internal pin in the larger size EIAJ plugs). The outer body of the plug is one contact, most often but not always the negative side of the supply. A pin mounted in the socket makes contact with a second internal contact. The outer plug contact is often called the sleeve, and the inner the tip, although the tip itself is actually non-conductive.
Many Different Sizes
There are many different sizes of these connectors. (See below.)
Contact ratings vary from unspecified (and probably less than 1 A in practice) up to 5 A, with 2 A typical. Voltage is again often unspecified, up to 48 V with 12 V typical. The smaller types usually have lower ratings, both for current and voltage.
It is quite possible that new sizes will continue to appear and disappear. The most likely reason for a new size is that a particular manufacturer wishes to discourage use of third-party power supplies, either for technical reasons or to promote use of their own products or both.
Furthermore, sometimes there is no rhyme or reason to the choice of which connector is used in an application. One manufacturer might use one size connector for its 12V 1A product; a second manufacturer might use a different connector for its 12V 1A product. Although the power supplies are otherwise identical, they are not interchangeable because the connectors are different.
Standards
Some organizations have proposed standards to minimize the market complexity. In an ideal world, specifying a voltage and a current for a power supply would also determine the connector.
At least two different national standards exist, EIAJ in Japan and DIN in Germany. As well several conventions have been adopted by specific manufacturers, notably by Sony, to indicate voltage by plug size.
Some manufacturers use opposite polarity standards, and some generic power supplies cater for this by allowing the polarity to be reversed by use of a switch or an unpolarized two-pin plug and socket arrangement. These two-pin plugs seem to be standardized but official specifications are hard to find. The pins are 1.5 mm in diameter, 6 mm long and spaced 4.2 mm apart. (see Egston connector overview (pdf), page 6, number 230)
Universal Power Supplies
Power adapters (or wall warts) have become almost universal. They free product designers from worrying about some safety issues. The designer builds his product to run off a low voltage (obtained through the coaxial power connector) and does not have to worry about hazardous voltages. One disadvantage of power adapters is they get separated from the product. Consequently, there is a market for replacement adapters. Not only must the consumer match voltage and current requirements, but he must also match the connector.
Some power supplies allow the voltage to be switched. That eases the voltage matching problem.
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