Single Conductor Cables (Hook-Up Wire)

Image	Part Number	Description / PDF	Quantity	Rfq
	1000600092 Woodhead - Molex	HOOK-UP SOLID 34AWG GREEN	0
	1000600095 Woodhead - Molex	HOOK-UP SOLID 34AWG WHITE	0
	1000600099 Woodhead - Molex	HOOK-UP STRND 36AWG YELLOW	0
	1000600100 Woodhead - Molex	HOOK-UP STRND 36AWG GREEN	0
	1000600101 Woodhead - Molex	HOOK-UP STRND 36AWG BLUE	0
	1000600091 Woodhead - Molex	HOOK-UP SOLID 34AWG YELLOW	0
	1000600098 Woodhead - Molex	36 AWG 2 MIL WALL RED	0
	1000600090 Woodhead - Molex	HOOK-UP SOLID 34AWG RED	0
	1000600104 Woodhead - Molex	HOOK-UP STRND 36AWG YELLOW	0
	1000600094 Woodhead - Molex	HOOK-UP SOLID 34AWG BLACK	0
	1000600097 Woodhead - Molex	36 AWG 2 MIL WALL BROWN	0
	1000600198 Woodhead - Molex	HOOK-UP STRND 36AWG GRAY	0
	1000600103 Woodhead - Molex	HOOK-UP STRND 36AWG ORANGE	0
	1000600107 Woodhead - Molex	HOOK-UP STRND 36AWG GRAY	0
	1000600087 Woodhead - Molex	HOOK-UP SOLID 32AWG BLUE	0
	1000600089 Woodhead - Molex	HOOK-UP SOLID 34AWG BROWN	0
	1000600270 Woodhead - Molex	HOOK-UP STRND 36AWG WHITE	0
	1000600269 Woodhead - Molex	PFA 36H07S 0.002 WALL BLACK	0
	1000600108 Woodhead - Molex	HOOK-UP STRND 36AWG BLACK	0
	1000600102 Woodhead - Molex	HOOK-UP STRND 36AWG RED	0

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.