Single Conductor Cables (Hook-Up Wire)

Part Number	Description / PDF	Quantity
30-00566 Tensility International Corporation	CBL 1COND STRND 22AWG GRAY 1000'	0
30-00559 Tensility International Corporation	CBL 1COND STRND 18AWG WHT 1000'	0
30-00339 Tensility International Corporation	CBL 1COND STRND 20AWG WHT 3.28'	48
30-00561 Tensility International Corporation	CBL 1COND STRND 20AWG BLK 3.28'	3
30-00574 Tensility International Corporation	CBL 1COND STRND 28AWG WHT 1000'	0
30-00336 Tensility International Corporation	CBL 1COND STRND 18AWG WHT 1000'	10
30-00557 Tensility International Corporation	CBL 1COND STRND 16AWG GRAY 1000'	0
30-00575 Tensility International Corporation	CBL 1COND STRND 28AWG GRAY 1000'	0
30-00562 Tensility International Corporation	CBL 1COND STRND 20AWG WHT 1000'	0
30-00344 Tensility International Corporation	CBL 1COND STRND 24AWG BLK 1000'	4
30-00555 Tensility International Corporation	CBL 1COND STRND 16AWG BLK 1000'	7
30-00571 Tensility International Corporation	CBL 1COND STRND 26AWG WHT 1000'	0
30-00564 Tensility International Corporation	CBL 1COND STRND 22AWG BLK 3.28'	17
30-00347 Tensility International Corporation	CBL 1COND STRND 26AWG BLK 1000'	4
30-00346 Tensility International Corporation	CBL 1COND STRND 24AWG CLR 3.28'	46

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.