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Decoding the Manufacturing Process of Network Jumpers: From Injection Molding to Testing
Release time:
2022-01-10 13:38
Author：
Editor
1、 Raw material selection: Good lines come from good materials
The core raw materials for network jumpers include:
Conductor: High purity oxygen free copper (OFC), purity ≥ 99.95%, ensuring low loss transmission
Insulation: HDPE foam insulation layer, low dielectric constant, excellent electrical performance
Sheath: PVC or LSZH material, meeting flame retardant and environmental protection requirements
Crystal head: phosphor bronze gold-plated terminal, with a gold plating thickness of 50 μ ", ensuring plug and unplug life
2、 Wire processing: precision determines quality
2.1 Cutting Line
Accurately cut according to the required length, with a tolerance controlled within ± 5mm, the fully automatic cutting machine can produce tens of thousands of pieces per day.
2.2 Wire stripping
Peel off the outer sheath to expose 4 pairs of twisted pair wires, with a stripping length of 25-30mm, without damaging the internal insulation layer and conductor.
2.3 Line management/branching
Arrange the line sequence according to T568B standard: orange white orange green white blue blue white green brown white brown. The accuracy of line sequence directly determines the availability of jumper wires and is a key quality control node.
3、 End connection process: precise operation between millimeters
Trim the 8-core wire neatly to about 14mm, push it into the corresponding slot of the RJ45 crystal head, and use a dedicated crimping tool to crimp it. The terminal blade punctures the insulation layer and forms an electrical connection with the conductor, and the buckle fixes the cable to prevent loosening.
High quality crimping standard:
All 8 cores are in place without any tilting or inability to reach the top
The crimping point is firm, and the tensile test is ≥ 50N
On resistance ≤ 20m Ω
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