Wave Crimp Power System

Ride the wave of power

Designed to address higher power needs, Wave Crimp is versatile and flexible. Able to bend and turn through almost any tight space, it is well suited to accommodate the shift from PCB to cable or bus bar for power distribution within a system.

Wave Crimp is a power connector system that features an insulated flat copper cable and a versatile range of associated interface components. The name Wave Crimp is derived from the multiple “waves” that are created in the flat cable conductor during termination of contact components on the prepared cable. The family of Wave Crimp interconnections offer value engineered solutions for power supply and distribution connectivity in mid-range systems. Because the surface area of flat cable is twice that of an equivalent round wire, convective heat flow reduces the operating temperature of the conductor for a given current, resulting in higher current capacity.

Wave Crimp Connections
The variety of Wave Crimp interfaces available make flat copper cable a versatile and innovative systems solution for power distribution.

Wave Crimp Facts

  • Termination of flat cable requires no stripping.
  • Provides a reliable, low resistance, gas-tight interface.
  • Separable interfaces have positive locking, polarization and contact shrouding.
  • Improved heat dissipation resulting in higher current capacity or reduced operating temperature.
  • Low inductance, high capacitance power distribution.
  • Packaging flexibility.
  • Less copper, therefore less weight and cost per ampere of rated current. 
  • Fully touch-safe.
The wave
The sheared cable “wave” edges contact the copper inserts.
Termination with the wave.
Over the life of the termination, resistance is expected to vary no more than 20 micro ohms.

The Wave Explained

The most unique feature of this product line is the wave crimp itself. Comprised of a hard copper transition sandwiched between soft copper profile plates, it is forced closed on the prepared cable end. The resulting sheared edges of the cable make a termination interface larger in area than the cable cross section itself. For greater reliability, diamond shaped indents spread each wave, creating a stored energy crimp that is a mechanically sound, low resistance gas-tight interface without the need for cable stripping.
Multiple “waves” are created through the shearing action of the application tooling during termination. Multiple strips are created in an alternating up and down orientation exposing sheared edges which become the crimp interface. This results in a conductive surface area of 150% of the cable cross section.