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Single Conductor Cables (Hook-Up Wire)

Image Part Number Description / PDF Quantity Rfq
9506-100ORN

9506-100ORN

E-Z-Hook

TEST LEAD 18AWG 5000V ORG 100'

0
9501-100WTE

9501-100WTE

E-Z-Hook

TEST LEAD 28AWG 600V WHITE 100'

0
9504-100GRY

9504-100GRY

E-Z-Hook

TEST LEAD 22AWG 300V GRAY 100'

0
9506-100BRN

9506-100BRN

E-Z-Hook

TEST LEAD 18AWG 5000V BROWN 100'

0
9501-100ORN

9501-100ORN

E-Z-Hook

TEST LEAD 28AWG 600V ORANGE 100'

0
9506-100YEL

9506-100YEL

E-Z-Hook

TEST LEAD 18AWG 5000V YEL 100'

0
9501-100YEL

9501-100YEL

E-Z-Hook

TEST LEAD 28AWG 600V YELLOW 100'

0
9501-100VLT

9501-100VLT

E-Z-Hook

TEST LEAD 28AWG 600V VIOLET 100'

0
9504-100BLU

9504-100BLU

E-Z-Hook

TEST LEAD 22AWG 300V BLUE 100'

0
9506-100VLT

9506-100VLT

E-Z-Hook

TEST LEAD 18AWG VIOLET 100'

0
9506-1000GRY

9506-1000GRY

E-Z-Hook

TEST LEAD 18AWG 5000V GRAY 1000'

0
9501-100GRY

9501-100GRY

E-Z-Hook

TEST LEAD 28AWG 600V GRAY 100'

0
9506-100WTE

9506-100WTE

E-Z-Hook

TEST LEAD 18AWG 5000V WHITE 100'

0
9506-100BLU

9506-100BLU

E-Z-Hook

TEST LEAD 18AWG 5000V BLUE 100'

0
9504-100BLK

9504-100BLK

E-Z-Hook

TEST LEAD 22AWG 300V BLACK 100'

114
9501-100GRN

9501-100GRN

E-Z-Hook

TEST LEAD 28AWG 600V GREEN 100'

0
9506-100GRN

9506-100GRN

E-Z-Hook

TEST LEAD 18AWG 5000V GREEN 100'

0
9504-500RED

9504-500RED

E-Z-Hook

TEST LEAD 22AWG 300V RED 500'

0
9506-1000VLT

9506-1000VLT

E-Z-Hook

TEST LEAD 18AWG VIOLET 1000'

0
9506-100GRY

9506-100GRY

E-Z-Hook

TEST LEAD 18AWG 5000V GRAY 100'

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.

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