Common Ribbon Cable Types

Ribbon cables consist of multiple small wires placed parallel to each other, creating a wide and flat design similar to a ribbon. Common pitch sizes include 0.635mm, 1.0mm, 1.27mm, and 2.0mm. These cables are typically used with IDC (insulation displacement connectors).

• Gray ribbon cable (UL Style: 2651, 2678, 2468, 20080): A type of ribbon cable that are gray in color, with red edge to prevent reverse connection.
• Rainbow ribbon cable (UL Style: 2651): A type of ribbon cable with small wires in mutiple colors each. The colors are placed in order of brown, red, orange, yellow, green, blue, violet, gray, white, and black. After that, the colors repeat.
• Round to flat ribbon cable (UL Style: 20381, 20267): A type of ribbon cable with round jacket, shielded or non-shielded. Designed to combine the benefits of round and flat cables, providing flexibility, manageability, mass termination, and maintaining efficient data transmission capabilities.
• Low-voltage ribbon cable (UL Style: 20080): 30V ribbon cable. Internal wiring used in in audio, video and electronic equipment.
• Halogen-free ribbon cable (UL Style: 20080, 20089): Halogen-free ribbon cables are a specialized type of ribbon cable designed without halogen-containing materials in their construction. These cables offer a safer alternative by reducing the emission of toxic gases and smoke in the event of a fire.

Ribbon Cable Connector Types

A ribbon cable connector links ribbon cables to electronic devices and circuit boards. Using insulation displacement connectors (IDC), it creates secure connections by pressing the cable onto sharp blades within the connector.

• IDC socket: IDC [An insulation-displacement contact, also known as insulation-piercing contact (IPC)] socket is a type of female connector that connects with flat ribbon cable, and then usually mates with a PCB header for wire to board connection.
• IDC transition headers: IDC transition header is a type IDC connector with pins that straightly soldered onto printed circuit board, to achieve a wire on board connection.
• D-Subminiature Connectors: Also known as D-sub connectors. It is a type of electrical connector with a D-shaped metal shield. D-sub connectors can be catagoried into male, female in gender; and wire connector, board connector in installation.
• Crimp style connectors: The contacts and housing of a crimp style connector are separate before connecting with wires. The contacts crimp wires and then the crimped wires are inserted into connector housing.

Ribbon Cable Benefits

Space Efficiency

Flat ribbon cables are designed to save space within your machinery or device, making them perfect for compact environments.

Ease of Installation

The parallel configuration of wires in a flat ribbon cable makes them straightforward to install, reducing labor costs and time.

Improved Organization

They help keep your wiring organized, minimizing the mess of individual wires and improving overall system maintenance.

Flexibility

These cables are highly flexible, allowing for easy routing in tight spaces and around corners without compromising performance.

Cost-Effectiveness

During production, flat ribbon cables can be manufactured in large quantities with standardized configurations from 2x2 pin to 2x32 pin, reducing manufacturing costs. Additionally, termination using Insulation Displacement Connectors (IDC) is straightforward, further cutting down on labor costs.

Ribbon Cable Applications

Computing: Internal connections in PCs and laptops

Consumer Electronics: Connections in home appliances and audio equipment

Automotive: Wiring harnesses and infotainment systems

Telecommunications: Network equipment and routers

Medical Devices: Diagnostic equipment and wearable devices

Industrial Automation: Control panels and machinery

Aerospace: Avionics and onboard systems

Military: Tactical communication equipment and navigation systems

Robotics: Interfacing sensors and actuators

Gaming: Consoles and peripheral devices

How to save cost when designing a ribbon cable assembly?

Saving costs during the design stage of a ribbon cable assembly is crucial. A bad design can harm your business by reducing profit margins and making your products less competitive. Inefficient designs lead to excessive material waste and higher labor costs.

Here are some tips to help you achieve that:

1. Standardize Components: Use standard connectors and cables to avoid custom manufacturing costs.

2. Simplify Design: Minimize the number of layers and conductors in the cable.

3. Optimize Length: Design cables to the exact required length to reduce material waste.

4. Choose Cost-Effective Materials: Select materials that balance performance and cost, like using less expensive insulations where high performance is not critical.

5. Batch Production: Plan for bulk production to take advantage of economies of scale.

6. Design for Manufacturability: Ensure the design is easy to produce with minimal steps and standard tools.

7. Vendor Collaboration: Work closely with suppliers to leverage their expertise and get cost-saving suggestions.

8. Prototype Testing: Conduct thorough testing on prototypes to identify and rectify potential issues early, avoiding costly redesigns.

9. Eliminate Unnecessary Features: Focus on essential features to keep the design simple and cost-effective.

10. Regulatory Compliance: Ensure designs meet regulatory standards to avoid expensive reworks.