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Jumper Wires, Pre-Crimped Leads

Image Part Number Description / PDF Quantity Rfq
AJWPSTJWPST18K51

AJWPSTJWPST18K51

JST

JUMPER SJWPST-21T-M1.0N X2 2"

0
ASPNISPNI22K254

ASPNISPNI22K254

JST

JUMPER SPNI-001T-P0.5 X2 10"

0
ASFHSFH22K305

ASFHSFH22K305

JST

JUMPER SSFH-001T-P0.5 X2 12"

0
ASRSFSRSF12K305B

ASRSFSRSF12K305B

JST

JUMPER SRSF-91T-250AS X2 12"

0
ASPLISPLI22K203

ASPLISPLI22K203

JST

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

0
ASFHSFH22K152

ASFHSFH22K152

JST

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

0
ASPNDSPND22K152

ASPNDSPND22K152

JST

JUMPER SPND-001T-C0.5 X2 6"

0
AJWPSTJWPSR18K51

AJWPSTJWPSR18K51

JST

JUMPER JWPS MALE TO FEMALE 2"

0
ARASRSFRASRSF16K203A

ARASRSFRASRSF16K203A

JST

JUMPER RASRSF-61-250A 8"

0
ASRSFSRSF12K102B

ASRSFSRSF12K102B

JST

JUMPER SRSF-91T-250AS X2 4"

0
AXLXL18K305P

AXLXL18K305P

JST

JUMPER SYM-41T-P0.7 X2 12"

0
ASZPDSZPD24K102

ASZPDSZPD24K102

JST

JUMPER SZPD-002T-P0.3 X2 4"

0
ASPSMSPSM16K254

ASPSMSPSM16K254

JST

JUMPER SPSM-41T-M1.1 X2 10"

0
ASRSFSRSF12K152B

ASRSFSRSF12K152B

JST

JUMPER SRSF-91T-250AS X2 6"

0
ASPSMSPSM16K152

ASPSMSPSM16K152

JST

JUMPER SPSM-41T-M1.1 X2 6"

0
AJWPSRJWPSR18K203

AJWPSRJWPSR18K203

JST

JUMPER SJWPSR-21T-P1.0 X2 8"

0
AXLXL18K203P

AXLXL18K203P

JST

JUMPER SYM-41T-P0.7 X2 8"

0
AJWPSRJWPSR18K102

AJWPSRJWPSR18K102

JST

JUMPER SJWPSR-21T-P1.0 X2 4"

0
ASVFSVF14K102

ASVFSVF14K102

JST

JUMPER SVF-61T-P2.0 X2 4"

962
ASVFSVF14K254

ASVFSVF14K254

JST

JUMPER SVF-61T-P2.0 X2 10"

444

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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