Single Conductor Cables (Hook-Up Wire)

Part Number	Description / PDF	Quantity
7671340 SAB North America	HOOK-UP STRND 12AWG BLK QTY1=1'	1257
31672790 SAB North America	HOOKUP STRN 4AWG GRN/YLW QTY1=1'	4156
31672784 SAB North America	HOOKUP STRND 14AWG GR/YL QTY1=1'	9923
31670286 SAB North America	HOOK-UP STRND 12AWG BLUE QTY1=1'	7340
31662750 SAB North America	HOOKUP STRND 20AWG GR/YL QTY1=1'	41171
1130257 SAB North America	HIGH TEMP WIRE 14AWG RED QTY1=1'	190
31670186 SAB North America	HOOK-UP STRND 12AWG BLK QTY1=1'	13999
31670284 SAB North America	HOOK-UP STRND 14AWG BLUE QTY1=1'	23822
31670888 SAB North America	HOOK-UP STRND 8AWG WHITE QTY1=1'	1806
31670182 SAB North America	HOOK-UP STRND 16AWG BLK QTY1=1'	36622
31670887 SAB North America	HOOK-UP STRND 10AWG WHT QTY1=1'	14526
31671688 SAB North America	HOOK-UP STRND 8AWG BLUE QTY1=1'	2410
31670487 SAB North America	HOOK-UP STRND 10AWG GRAY QTY1=1'	9617
31671187 SAB North America	HOOK-UP STRND 10AWG RED QTY1=1'	9609
31670191 SAB North America	HOOK-UP STRND 2AWG BLACK QTY1=1'	3640
31663250 SAB North America	HOOKUP STRND 20AWG BL/WH QTY1=1'	6170
31872782 SAB North America	H07Z-K 16AWG GN/YE QTY1=1'	32280
7671366 SAB North America	HOOK-UP STRND 2/0AWG BLK QTY1=1'	2396
7671363 SAB North America	HOOK-UP STRND 4AWG BLACK QTY1=1'	529
31661680 SAB North America	HOOK-UP STRND 18AWG BLUE QTY1=1'	18491

Single Conductor Cables (Hook-Up Wire)

1. Overview

Single conductor cables, also known as hook-up wires, are insulated electrical conductors used for low-current signal and power transmission in electronic devices. They serve as fundamental components for internal wiring in PCBs, appliances, and control systems. Their importance lies in enabling reliable electrical connections while maintaining space efficiency and design flexibility in modern electronics.

2. Main Types and Functional Classification

Type	Functional Characteristics	Application Examples
PVC-Insulated Wire	Cost-effective, flexible, 105 C temperature rating	Consumer electronics, HVAC systems
Silicone Rubber Insulated Wire	High flexibility (-55 C to 200 C), excellent thermal resistance	Industrial ovens, medical devices
PTFE/Teflon Insulated Wire	Chemical resistance, 200 C operational stability	Aerospace sensors, chemical processing equipment
High-Temperature Wire	Special polymer jackets for 150-300 C environments	Automotive engine compartments, lighting ballasts
Shielded Hook-Up Wire	Braided/aluminum foil shielding for EMI protection	Telecommunications equipment, measurement instruments

3. Structure and Composition

Typical construction includes:

Conductor: Annealed copper (most common), aluminum, or tinned copper (stranded or solid)
Insulation: Thermoplastic (PVC, polyethylene), thermoset (silicone rubber), or fluoropolymer materials
Shielding: Optional braided copper/aluminum foil layer for EMI protection
Jacket: Abrasion-resistant outer layer (PVC, polyurethane) in specific variants

Stranded conductors (e.g., 7/30, 19/34 stranding) optimize flexibility while maintaining conductivity.

4. Key Technical Specifications

Parameter	Description	Importance
Conductor Gauge (AWG/mm )	Defines current-carrying capacity (e.g., 30 AWG to 10 AWG)	Determines power transmission capability
Insulation Thickness	0.1-0.8 mm depending on voltage rating	Ensures dielectric strength and safety
Temperature Range	-65 C to 300 C operational limits	Dictates environmental suitability
Voltage Rating	30V to 1000V depending on insulation material	Safety and insulation performance indicator
Bending Life	500-50,000 flex cycles (MIL-W-5088L standard)	Crucial for dynamic applications
Shielding Effectiveness	60-100 dB coverage (100 kHz-1 GHz)	EMI/RFI interference reduction metric

5. Application Fields

Consumer Electronics: PCB interconnects in smartphones, printers, and home appliances
Automotive: Sensor wiring, ABS system connections, battery management systems
Medical: ECG machine internal wiring, diagnostic equipment signal transmission
Industrial: PLC cabinet wiring, robotics joint connections
Aerospace: Avionics harnesses, flight control system terminations

6. Leading Manufacturers and Products

Manufacturer	Representative Product	Key Features
Alpha Wire (Alpha Technologies)	EZ-Hook 1385 Series	105 C PVC insulation, UL 1015/CSA Type TEW certification
Lapp Group	UNITRONIC LiYY	Oil-resistant PVC jacket, 300/500V rating
Panduit Corp.	Panfluor 200 Series	PTFE-insulated, meets FAA 25.853 flammability requirements
TE Connectivity	Raychem Hook-Up Wire	Heat-shrinkable insulation, aerospace qualified
Sumitomo Electric Industries	AeroElite Series	Lightweight composite insulation for aircraft wiring

7. Selection Recommendations

Key considerations:

Operating temperature range vs material thermal stability
Voltage/current requirements vs conductor cross-section
Mechanical stress environment (flexing, vibration)
Regulatory certifications (UL, CSA, MIL-SPEC)
Chemical exposure resistance (oil, coolant, cleaning agents)
EMI sensitivity requiring shielded variants

Example: Automotive engine control units typically require 150 C-rated silicone-insulated wires with vibration-resistant stranded conductors.

8. Industry Trend Analysis

Current development trends include:

Miniaturization: 32 AWG+ ultra-fine wires for wearable electronics
Material innovation: Halogen-free flame-retardant compounds
High-speed capability: Controlled impedance designs for data transmission
Automated manufacturing: Laser-marking and precision stripping compatibility
Sustainability focus: Recyclable insulation materials and lead-free production

The global hook-up wire market is projected to grow at 5.2% CAGR through 2027, driven by EV and IoT device demand according to MarketsandMarkets research.