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Flat Flex, Ribbon Jumper Cables

Flat Flex (also known as ribbon) jumper cables are a specialized type of electrical connector, used on devices that require a high-current connection with very low electrical resistance. They are used primarily in automotive, aerospace, medical and industrial applications. They are also used in a variety of other applications where a low-voltage, low-impedance, and reliable electrical contact is required.

Application Field

Flat flex cable assemblies are designed to provide low resistance electric connections between components and between boards or other electrical equipment. It is composed of an insulated ribbon cable with a connector on each end, and may also contain heat shrink tubing or additional wires, depending on the application. Flat flex cables are typically used in automotive, aerospace, medical and industrial applications. For example, they are used in automotive engines and fuel injection systems, avionics systems, medical imaging systems, industrial automation systems, and other equipment and medical devices.

Working Principle

Flat flex cables are designed to provide low resistance electrical connections between components and between boards or other electrical equipment. It is composed of an insulated ribbon cable with a connector on each end, and may also contain heat shrink tubing or additional wires depending on the application. The ribbon cable is composed of multiple conductors that are soldered together at either end of the cable, providing a single electrical contact. The conductors in the cable are placed in a pre-determined pattern to optimize the length of the electrical path and reduce electrical resistance. The connector at each end of the cable also includes an over-mold that seals the assembly and provides environmental protection.

The ribbon cable also consists of a dielectric material that separates each conductor and prevents electrical current from flowing between the conductors. This dielectric material also provides flexibility and protects the conductors from physical damage. The ribbon cable is also typically covered with a protective outer jacket or plenum sleeve that provides additional protection and insulation.

The connectors at each end of the cable may also contain an electrical polarity indicator, which is used to indicate the proper orientation of the mating parts. This indicator may also be used to prevent incorrect assembly of the parts, as well as provide visual feedback when assembling the components.