Single Conductor Cables (Hook-Up Wire)

Part Number	Description / PDF	Quantity
391645 WH005 Alpha Wire	HOOK-UP STRND 16AWG WHITE 100'	4
392245 RD002 Alpha Wire	HOOK-UP STRND 22AWG RED 500'	1
AT201932 BR001 Alpha Wire	HOOK-UP STRND 20AWG BROWN 1000'	2
461626 RD005 Alpha Wire	HOOK-UP STRND 16AWG RED 100'	1373
541201 GR001 Alpha Wire	HOOK-UP SOLID 12AWG GREEN 1000'	13
3080 RD005 Alpha Wire	HOOK-UP STRND 12AWG RED 100'	1850
5874 OR001 Alpha Wire	HOOK-UP STRND 24AWG ORANGE 1000'	6
3080 BK005 Alpha Wire	HOOK-UP STRND 12AWG BLACK 100'	49
1807 BL001 Alpha Wire	HOOK-UP SOLID 26AWG BLUE 1000'	2
5852 SL005 Alpha Wire	HOOK-UP STRND 28AWG SLATE 100'	23
781401 VI001 Alpha Wire	HOOK-UP SOLID 14AWG VIOLET 1000'	2
AT221934 BK005 Alpha Wire	HOOK-UP STRND 22AWG BLACK 100'	11
391862 WH005 Alpha Wire	HOOK-UP STRND 18AWG WHITE 100'	4
392040 RD002 Alpha Wire	HOOK-UP STRND 20AWG RED 500'	0
3055 YL001 Alpha Wire	HOOK-UP STRND 18AWG YELLOW 1000'	4
541801 RD005 Alpha Wire	HOOK-UP SOLID 18AWG RED 100'	6
1856 BR005 Alpha Wire	HOOK-UP STRND 20AWG BROWN 100'	5
6719 BR001 Alpha Wire	HOOK-UP STRND 10AWG BROWN 1000'	2
892019 VI002 Alpha Wire	HOOK-UP STRND 20AWG VIOLET 500'	3
1561/24 BK001 Alpha Wire	HOOK-UP SOLID 24AWG BLACK 1000'	8

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.