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Jumper Wires, Pre-Crimped Leads

Image Part Number Description / PDF Quantity Rfq
ASXALSXAL22K152

ASXALSXAL22K152

JST

JUMPER SXA-001T-P0.6L X2 6"

0
ASMPSMP22K254

ASMPSMP22K254

JST

JUMPER SHF-001T-0.8BS X2 10"

0
ASFHSFH22K51

ASFHSFH22K51

JST

JUMPER SSFH-001T-P0.5 X2 2"

0
ASMPSMP22K305

ASMPSMP22K305

JST

JUMPER SHF-001T-0.8BS X2 12"

0
ASPUDSPUD22K51

ASPUDSPUD22K51

JST

JUMPER SPUD-001T-P0.5 X2 2"

0
ASPUDSPUD22K152

ASPUDSPUD22K152

JST

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

0
ASXALSXAL22K203

ASXALSXAL22K203

JST

JUMPER SXA-001T-P0.6L X2 8"

0
ASXMSXAL22K102

ASXMSXAL22K102

JST

JUMPER SXM-001T/SXA-001T 4"

0
ASXMSXAL22K254

ASXMSXAL22K254

JST

JUMPER SXM-001T/SXA-001T 10"

0
ASXMSXM22K305

ASXMSXM22K305

JST

JUMPER SXM-001T-P0.6 X2 12"

0
ASXMSXM22K152

ASXMSXM22K152

JST

JUMPER SXM-001T-P0.6 X2 6"

0
ASFHSFH22K102

ASFHSFH22K102

JST

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

0
AJFPSJFPS12K305

AJFPSJFPS12K305

JST

JUMPER SJFPS-81T-M1.0 X2 12"

0
ASMPSMP22K51

ASMPSMP22K51

JST

JUMPER SHF-001T-0.8BS X2 2"

0
ASMPSMP22K203

ASMPSMP22K203

JST

JUMPER SHF-001T-0.8BS X2 8"

0
ASMRSMR22K305

ASMRSMR22K305

JST

JUMPER SYM-001T-P0.6 X2 12"

0
ASXALSXAL22K305

ASXALSXAL22K305

JST

JUMPER SXA-001T-P0.6L X2 12"

0
AJFPSJFPS12K51

AJFPSJFPS12K51

JST

JUMPER SJFPS-81T-M1.0 X2 2"

0
ASPSISPSI16K203

ASPSISPSI16K203

JST

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

0
ASXALSXAL22K102

ASXALSXAL22K102

JST

JUMPER SXA-001T-P0.6L X2 4"

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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