Method of forming a flat flexible jumper

摘要

A flat flexible jumper is made from a preformed strip of conductive material which is cut to the desired jumper configuration and covered by a layer of insulation. The preformed strip is formed of a series of raised zones and flat zones. A stamping process is executed on the preformed strip utilizing a series of cutting dies to form the desired jumper configuration of the preformed conductive strip. A first die cuts away the material in the flat zone of the preformed strip leaving the raised zone remaining. A second die cuts away a portion of the flat zone and a portion of the raised zone providing a first transition region between the raised zone and the flat zone. A third die cuts away the material in the raised zone of the preformed conductor strip leaving the flat zone remaining. A fourth die cuts away a portion of the raised zone and a portion of the flat zone providing the second transition region between the flat zone and the raised zone. After the cutting process, the jumper is covered in insulation to prevent undesired contact between each of the conductors of the jumper. Any number of conventional insulation application methods, such as extruding insulation around the jumper or laminating two layers of insulation around the central portion of the jumper, can be used.