Precision Square Non-Insulated Terminals Manufacturer
TONFUL Electric is a premier manufacturer of heavy-duty Square Non-Insulated Terminals (Bare Terminals), engineered for highly reliable, space-constrained wire terminations. Designed with a unique square or rectangular profile, these terminals sit perfectly flush within barrier terminal blocks, preventing accidental rotation and short circuits when mounting screws are tightened.
Without the bulk and temperature limitations of plastic insulation, our bare square terminals are ideal for extreme high-temperature environments, custom heat-shrink applications, and automated solder dipping. Manufactured from high-purity electrolytic copper with precision tin plating, TONFUL delivers maximum conductivity, superior corrosion resistance, and uncompromising mechanical strength for industrial machinery, automotive harnesses, and power distribution systems.
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Our Range of Square Non-Insulated Terminals
Square Non-Insulated Terminals
Square Non-Insulated Terminals
Technical Specifications: Square Non-Insulated Terminals
| Specification | Available Options / Parameters |
|---|---|
| Terminal Type (端子类型) | Square Non-Insulated Ring / Square Spade Terminal (Bare) |
| Wire Gauge Range (适用线径) | 22 AWG to 2/0 AWG (0.5mm² to 70mm²) |
| Material (材质) | High-Purity Electrolytic Copper / Brass |
| Contact Plating (表面镀层) | Electro-Tin Plated (Standard), Bare Copper, Silver Plated (Custom) |
| Operating Temperature (工作温度) | Up to +150°C (Tin-plated) / Up to +340°C (Bare Copper) |
| Termination Method (接线方式) | Crimp (Indent/Dimple style) or Solder |
| Insulation (绝缘) | None (Designed for use with Heat Shrink Tubing or bare applications) |
| Anti-Rotation Design (防转动) | Square edges lock into barrier strips |
| Compliance & Standards (认证) | RoHS, CE, ISO 9001 |
| OEM Customization (定制服务) | Custom stud hole sizes, specific metal thicknesses, custom angles |
Why Choose TONFUL Square Non-Insulated Terminals
Anti-Rotation Square Design
Standard round ring terminals can twist when the mounting screw is torqued down, potentially touching adjacent terminals and causing a short. Our square profile fits snugly within the walls of standard barrier terminal blocks, completely eliminating rotation and ensuring a safe, locked-in connection.
Extreme High-Temperature Tolerance
Standard insulated terminals use PVC or Nylon sleeves that melt at 105°C. By utilizing a completely non-insulated bare copper design, our terminals can operate safely in high-heat environments like engine compartments, industrial ovens, and heavy-duty power supplies without degrading.
Maximum Electrical Conductivity
We manufacture our terminals using premium high-purity electrolytic copper, not cheap alloys. This ensures the lowest possible electrical resistance, allowing for maximum current flow with minimal heat generation under heavy electrical loads.
Versatile Crimp & Solder Capabilities
Unlike insulated terminals that can only be crimped, our bare terminals offer total manufacturing flexibility. They can be mechanically crimped using a standard indent tool, or they can be fluxed and dip-soldered for an absolute gas-tight, corrosion-proof electrical bond.
Seamless Heat Shrink Integration
Many OEMs prefer to use bare terminals and apply their own heavy-duty Dual-Wall Adhesive Heat Shrink Tubing after crimping. Our non-insulated square terminals provide the perfect smooth, burr-free barrel for heat shrink to grip onto, creating an IP68 waterproof seal.
Factory-Direct Custom Stamping
As a direct manufacturer, TONFUL is not limited to standard catalog sizes. We possess in-house tooling capabilities to stamp custom square terminals with specific metal thicknesses, non-standard stud hole sizes, or custom bend angles (e.g., 45° or 90°) to fit your exact engineering drawings.
Professional Selection Guide
Step 1: Match the Wire Gauge (AWG / mm²)
The most critical step is ensuring the terminal barrel matches your wire size perfectly. Whether you are using thin 22 AWG signal wire or thick 2/0 AWG battery cable, select the exact barrel size to guarantee a secure crimp without wire strand breakage.
Step 2: Determine the Stud / Screw Size
Measure the diameter of the mounting stud or screw on your terminal block. The hole in the square terminal must be just large enough to fit over the stud tightly. Common sizes include #6, #8, #10, 1/4", and Metric sizes like M4, M5, M6, and M8.
Step 3: Measure the Terminal Block Width
Since this is a square terminal designed to sit inside a barrier strip, the outer width of the square terminal pad must be slightly smaller than the distance between the plastic dividing walls of your terminal block.
Step 4: Choose the Termination Method
Decide if your assembly line will mechanically crimp the terminals or solder them. If crimping bare terminals, ensure your technicians are using a specialized "non-insulated terminal crimper" (which creates a deep dimple/indent), rather than a standard insulated crimp tool.
Step 5: Plan for Post-Installation Insulation
Since the terminal is bare, evaluate if your application requires secondary insulation. If there is a risk of accidental contact or moisture, plan to slide a piece of Polyolefin Heat Shrink Tubing over the wire and the terminal barrel before making the connection.
Step 6: Confirm the Plating Requirement
Our standard electro-tin plating provides excellent corrosion resistance for 95% of applications. However, for extremely corrosive environments or highly specialized high-frequency signals, consult with us regarding custom silver or gold plating options.
| Item NO | Cable Size A.W.G | Thickness (mm) | Max Current | USA Screw | Screw Dia. d2(mm) | Dimension (mm) | |||||
|---|---|---|---|---|---|---|---|---|---|---|---|
| W | L | F | E | DΦ | dΦ | ||||||
| CB 22-5 | 16~25 (4) | 1.7 | 115A | #10 | 5.3 | 12.5 | 33.0 | 14.2 | 12.0 | 11.6 | 8.2 |
| CB 22-6 | 1/4 | 6.4 | |||||||||
| CB 22-8 | 5/16 | 8.4 | |||||||||
| CB 38-5 | 35~50 (2) | 1.8 | 160A | #10 | 5.3 | 13.0 | 38.0 | 16.2 | 14.0 | 13.3 | 9.4 |
| CB 38-6 | 1/4 | 6.4 | |||||||||
| CB 38-8 | 5/16 | 8.4 | |||||||||
| CB 60-8 | 50~70 (1/10) | 1.7 | 215A | 5/16 | 8.4 | 16.0 | 48.5 | 20.7 | 18.0 | 15.4 | 12.0 |
| CB 60-10 | 3/8 | 10.5 | |||||||||
| CB 70-8 | 70~95 (2/0) | 2.0 | 235A | 5/16 | 8.4 | 19.5 | 49.0 | 20.0 | 19.0 | 17.5 | 13.5 |
| CB 70-10 | 3/8 | 10.5 | |||||||||
| CB 80-8 | 95~120 (1/0) | 2.2 | 255A | 5/16 | 8.4 | 22.0 | 52.0 | 20.7 | 20.0 | 19.5 | 15.0 |
| CB 80-10 | 3/8 | 10.5 | |||||||||
| CB 80-12 | 1/2 | 13.0 | |||||||||
| CB 100-8 | 120~150 (4/0) | 2.6 | 300A | 5/16 | 8.4 | 22.0 | 53.5 | 20.3 | 21.0 | 22.5 | 17.0 |
| CB 100-10 | 3/8 | 10.5 | |||||||||
| CB 100-12 | 1/2 | 13.0 | |||||||||
| CB 150-8 | 150~185 (250/300) | 3.2 | 395A | 5/16 | 8.4 | 28.0 | 62.5 | 21.0 | 27.0 | 27.0 | 20.0 |
| CB 150-10 | 3/8 | 10.5 | |||||||||
| CB 150-12 | 1/2 | 13.0 | |||||||||
| CB 180-10 | 185~240 (300/350) | 3.5 | 440A | 3/8 | 10.5 | 29.0 | 65.5 | 21.2 | 28.5 | 28.6 | 21.0 |
| CB 180-12 | 1/2 | 13.0 | |||||||||
| CB 200-10 | 240~300 (400/500) | 4.0 | 470A | 3/8 | 10.5 | 33.0 | 73.0 | 24.3 | 31.5 | 32.6 | 24.0 |
| CB 200-12 | 1/2 | 13.0 | |||||||||
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MORE THAN JUST A SQUARE NON-INSULATED TERMINAL MANUFACTURER
Service Consultation
Whether your Square Non-Insulated Terminals requirements are straightforward or complex, our team provides expert advice and technical consultation. For more intricate projects, we offer in-depth engineering support to ensure optimal product selection and application, guaranteeing safety and efficiency in your electrical systems.
Product Recommendations
Unsure which Square Non-Insulated Terminal suits your system? Our specialists provide free, customized recommendations based on your specific operational and environmental requirements, ensuring you get the perfect fit for your electrical protection needs.
Installation Support
Need help with installation? Our technical team is available to answer your questions or provide hands-on support. For larger projects, we can even dispatch an engineer to your site for on-the-ground assistance, ensuring your Square Non-Insulated Terminals are installed correctly and function seamlessly within your electrical network.
Logistics Support
If you lack a reliable freight forwarder, we can arrange transportation from our factory to your project site at no extra cost. Our logistics team ensures timely and secure delivery to keep your project on schedule, minimizing downtime and delays.
Frequently Asked Questions
We have compiled some common questions from our clients. If your question isn’t included here, our customer service is always available to help. We’d love to talk with you.
Q1: Why should I choose a non-insulated terminal over an insulated one?
Non-insulated terminals are chosen for three main reasons: 1) High temperatures (no plastic sleeve to melt). 2) Space constraints (the bare barrel is thinner than an insulated one). 3) Custom sealing (they allow engineers to apply dual-wall adhesive heat shrink tubing over the crimp for complete waterproofing).
Q2: What is the benefit of the "Square" shape?
The square or rectangular head is specifically designed to sit flat against the plastic dividing walls of a barrier terminal block. When you tighten the screw, the wall prevents the terminal from spinning. A standard round terminal might spin and touch the neighboring wire, causing a short circuit.
Q3: Can I use a standard crimping tool for these bare terminals?
No. You must use a crimper specifically designed for non-insulated terminals. These tools feature a “dimple” or “indent” die that pushes deeply into the bare metal barrel, crushing the wire strands together for a solid mechanical and electrical bond.
Q4: Can these non-insulated terminals be soldered instead of crimped?
Yes, absolutely! Because there is no plastic insulation in the way, our bare copper terminals are highly suitable for wave soldering, dip soldering, or manual soldering to achieve a flawless connection.
Q5: Will bare copper terminals rust or oxidize?
Bare copper will eventually oxidize if exposed to the elements. That is why TONFUL standardizes on Electro-Tin Plated copper. The tin plating provides a robust, highly conductive layer that prevents oxidation and corrosion, ensuring a long lifespan even in harsh environments.
Q6: Does TONFUL offer custom stamping for unique terminal shapes?
Yes. We have complete in-house tooling and stamping capabilities. If you need a square terminal with a specific bend angle, an unusual stud hole size, or extra-thick metal for high-current applications, we can manufacture it to your exact OEM specifications.
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