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Jumper Wires, Pre-Crimped Leads

Image Part Number Description / PDF Quantity Rfq
ASXNISXNI22K102

ASXNISXNI22K102

JST

JUMPER SXNI-001T-P0.6 X2 4"

0
ARASRSFRASRSF16K152B

ARASRSFRASRSF16K152B

JST

JUMPER RASRSF-61T-250A 6"

0
ASBHMSBH22K305

ASBHMSBH22K305

JST

SBH-001T-P0.5-SBHM-001T-P0.5 12"

2000
ASRSFSRSF12K102A

ASRSFSRSF12K102A

JST

JUMPER SRSF-91-250AS X2 4"

0
ASVMSVM14K203

ASVMSVM14K203

JST

JUMPER SVM-61T-P2.0 X2 8"

1000
ASMRSMP22K254

ASMRSMP22K254

JST

JUMPER SYM-001/SHF-001 10"

0
ASBHMSBHM22K152

ASBHMSBHM22K152

JST

JUMPER SBHM-001T-P0.5 X2 6"

2000
ANSHDNSHD28K203

ANSHDNSHD28K203

JST

JUMPER SNSHD-003T-P0.2 X2 8"

0
ARASRSFRASRSF20K152A

ARASRSFRASRSF20K152A

JST

JUMPER RASRSF-21-250A 6"

0
ASRSFSRSF12K254B

ASRSFSRSF12K254B

JST

JUMPER SRSF-91T-250AS X2 10"

0
AWPJWPJ18K152R

AWPJWPJ18K152R

JST

JUMPER SWPJR-21T-M0.5 X2 6"

0
ASRSFSRSF20K254A

ASRSFSRSF20K254A

JST

JUMPER SRSF-21-250A X2 10"

0
ASPUDSPUD22K203

ASPUDSPUD22K203

JST

JUMPER SPUD-001T-P0.5 X2 8"

0
AXLXL18K51P

AXLXL18K51P

JST

JUMPER SYM-41T-P0.7 X2 2"

0
AWPJWPJ18K152T

AWPJWPJ18K152T

JST

JUMPER SWPJT-21T-P0.5 X2 6"

0
AXLXL18K102S

AXLXL18K102S

JST

JUMPER SXF-41T-P0.7 X2 4"

0
ASBHMSBHM22K203

ASBHMSBHM22K203

JST

JUMPER SBHM-001T-P0.5 X2 8"

0
AXLXL18K152P

AXLXL18K152P

JST

JUMPER SYM-41T-P0.7 X2 6"

0
ASRSFSRSF16K203B

ASRSFSRSF16K203B

JST

JUMPER SRSF-61T-250A X2 8"

0
ASXASXA22K254

ASXASXA22K254

JST

JUMPER SXA-01T-P0.6 X2 10"

652

Jumper Wires, Pre-Crimped Leads

1. Overview

Jumper wires and pre-crimped leads are essential components in electrical and electronic systems, providing flexible, reliable connections between devices, circuits, or components. These cable assemblies consist of conductive wires terminated with crimped connectors or contacts, enabling quick and secure electrical connections without soldering. Their importance spans industries such as telecommunications, automotive, industrial automation, and consumer electronics, where modularity, ease of installation, and maintenance are critical.

2. Major Types and Functional Classification

TypeFunctional FeaturesApplication Examples
Single-Core Jumper WiresSimplex conductors with insulation, ideal for low-current signal transmissionPrototyping breadboards, PCB interconnects
Multi-Core Cable AssembliesMultiple insulated conductors bundled in a common jacket for parallel signal/data transmissionComputer peripherals, industrial sensors
Shielded Jumper CablesIntegrated electromagnetic interference (EMI) shielding for noise-sensitive applicationsAudio equipment, high-speed data lines
High-Temperature LeadsHeat-resistant materials (e.g., silicone rubber or PTFE insulation) for extreme environmentsAutomotive engine control units, aerospace systems
DIN/Standardized ConnectorsCompliant with IEC/DIN standards for universal compatibilityMedical devices, test equipment

3. Structure and Components

A typical jumper wire or pre-crimped lead assembly consists of three primary elements:

  1. Conductor: Stranded or solid copper wire (e.g., AWG 20-28) for optimal flexibility and conductivity.
  2. Insulation: Thermoplastic (PVC, TPE) or high-temperature materials (FEP, silicone) to prevent electrical leakage.
  3. Crimped Termination: Pre-assembled contacts or connectors (e.g., pin headers, spade terminals) mechanically secured via crimping tools.

Additional features may include strain reliefs, color-coded jackets for circuit identification, and overmolded strain reliefs for durability.

4. Key Technical Specifications

ParameterImportance
Conductor Gauge (AWG)Determines current-carrying capacity and flexibility
Current Rating (A)Maximum safe operating current
Voltage Rating (V)Dielectric strength of insulation material
Temperature Range ( C)Operational limits in harsh environments
Contact Resistance (m )Affects signal integrity and power efficiency
Insulation Resistance (M )Prevents leakage currents
Crimp Pull-Out Force (N)Mechanical stability of termination

5. Application Fields

  • Electronics Manufacturing: PCB testing, jumper connections in consumer devices.
  • Automotive: Wiring harnesses for sensors, battery management systems.
  • Telecommunications: Patch cables for routers, switches, and base stations.
  • Industrial Automation: Connection of PLCs, HMIs, and motor drives.
  • Medical Devices: Patient monitoring equipment and diagnostic tools.

6. Leading Manufacturers and Products

ManufacturerRepresentative Products
TE ConnectivityAMPMODU pre-crimped jumper cables, high-temperature automotive leads
MolexMicro-Fit 3D pre-assembled jumper wires for industrial controls
AmphenolRF coaxial jumper cables for telecom infrastructure
Phoenix ContactPrinted circuit board connectors with pre-crimped leads
3MHigh-density shielded cable assemblies for data centers

7. Selection Guidelines

When selecting jumper wires or pre-crimped leads, consider:

  1. Application Requirements: Signal type (analog/digital), voltage/current levels, and environmental conditions.
  2. Compatibility: Connector types (e.g., USB, HDMI, proprietary headers) and mating cycles.
  3. Cost vs. Performance: Balance material quality (e.g., oxygen-free copper) against budget constraints.
  4. Supplier Support: Availability of customization, volume pricing, and technical documentation.

Case Study: In an automotive test system, shielded high-temperature leads with 16 AWG conductors and silicone insulation ensured reliable data transmission at 150 C.

8. Industry Trends

  • Miniaturization: Growth in ultra-fine AWG 34+ cables for wearable devices and IoT sensors.
  • High-Speed Data Transmission: Development of controlled-impedance jumpers for 10+ Gbps applications.
  • Automation Integration: Standardized pre-crimped leads compatible with robotic assembly systems.
  • Sustainability: Adoption of halogen-free insulation and recyclable materials.
  • Smart Cables: Embedded sensors for real-time monitoring of temperature and current.
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