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Jumper Wires, Pre-Crimped Leads

Image Part Number Description / PDF Quantity Rfq
ASYMSYM16K203

ASYMSYM16K203

JST

JUMPER SYM-41T-P0.5A X2 8"

980
AXLXL18K152S

AXLXL18K152S

JST

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

0
ASPSMSPSM16K203

ASPSMSPSM16K203

JST

JUMPER SPSM-41T-M1.1 X2 8"

0
ASPSISPSM16K102

ASPSISPSM16K102

JST

SPSM-41T-M1.1 - SPSI-41T-M1.1 4"

0
ASXNISXNI22K203

ASXNISXNI22K203

JST

JUMPER SXNI-001T-P0.6 X2 8"

0
ASPLISPLI22K102

ASPLISPLI22K102

JST

JUMPER SPLI-001T-P0.5 X2 4"

0
ARASRSFRASRSF16K102B

ARASRSFRASRSF16K102B

JST

JUMPER RASRSF-61-250A 4"

0
ASPNDSPNI22K254

ASPNDSPNI22K254

JST

SPND-001T-C0.5-SPNI-001T-P0.5 10

0
ASYMSYM16K102

ASYMSYM16K102

JST

JUMPER SYM-41T-P0.5A X2 4"

950
AXLXL18K102P

AXLXL18K102P

JST

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

0
ASHDSHD28K51

ASHDSHD28K51

JST

JUMPER SSH-003GA-P0.2-H X2 2"

0
ARASRSFRASRSF20K305B

ARASRSFRASRSF20K305B

JST

JUMPER RASRSF-21T-250A 12"

0
ASRSF2X16K152A

ASRSF2X16K152A

JST

JUMPER SRSF-82-250A 6"

277
ANSHDNSHD28K152

ANSHDNSHD28K152

JST

JUMPER SNSHD-003T-P0.2 X2 6"

0
ASMRSMP22K203

ASMRSMP22K203

JST

JUMPER SYM-001/SHF-001 8"

0
ASPSISPSM16K152

ASPSISPSM16K152

JST

SPSM-41T-M1.1 - SPSI-41T-M1.1 6"

0
AWPJWPJ18K203T

AWPJWPJ18K203T

JST

JUMPER SWPJT-21T-P0.5 X2 8"

0
APADPAD22K51

APADPAD22K51

JST

JUMPER SPH-001T-P0.5L X2 2"

0
AJWPSRJWPSR18K152

AJWPSRJWPSR18K152

JST

JUMPER SJWPSR-21T-P1.0 X2 6"

0
ASZPDSZPD24K152

ASZPDSZPD24K152

JST

JUMPER SZPD-002T-P0.3 X2 6"

0

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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