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Wire Wrap

Image Part Number Description / PDF Quantity Rfq
R-30W-0050

R-30W-0050

OK Industries (Jonard Tools)

WIRE WW 30AWG PVDF WHITE 50'

18
W28-6BU

W28-6BU

Vector Electronics & Technology, Inc.

WIRE WW 28AWG ETFE RED 150'

75
R28BLK-0100

R28BLK-0100

OK Industries (Jonard Tools)

WIRE WW 28AWG PVDF BLACK 100'

73
30-R-50-020

30-R-50-020

OK Industries (Jonard Tools)

WIRE WW 30AWG PVDF RED 4" 50PC

520
30-Y-50-050

30-Y-50-050

OK Industries (Jonard Tools)

WIRE WW 30AWG PVDF YELLW 7" 50PC

24
KSW28B-0100

KSW28B-0100

OK Industries (Jonard Tools)

WIRE 28AWG BLUE 100 FT CSW

3
30-W-50-010

30-W-50-010

OK Industries (Jonard Tools)

WIRE WW 30AWG PVDF WHITE 3" 50PC

7
R30Y-1000

R30Y-1000

OK Industries (Jonard Tools)

WIRE WW 30AWG PVDF YELLOW 1000'

6
R28W-0100

R28W-0100

OK Industries (Jonard Tools)

WIRE WW 28AWG PVDF WHITE 100'

15
W28-6A

W28-6A

Vector Electronics & Technology, Inc.

WIRE WW 28AWG ETFE GRN 50' 2/PK

3
30-Y-50-030

30-Y-50-030

OK Industries (Jonard Tools)

WIRE WW 30AWG PVDF YELLW 5" 50PC

78
R28R-0100

R28R-0100

OK Industries (Jonard Tools)

WIRE WW 28AWG PVDF RED 100'

48
KSW26R-0100

KSW26R-0100

OK Industries (Jonard Tools)

WIRE 26AWG RED 100 FT CSW

26
R-30B-0050

R-30B-0050

OK Industries (Jonard Tools)

WIRE WW 30AWG PVDF BLUE 50'

52
R30W-1000

R30W-1000

OK Industries (Jonard Tools)

WIRE WW 30AWG PVDF WHITE 1000'

25
R26Y-0100

R26Y-0100

OK Industries (Jonard Tools)

WIRE WW 26AWG PVDF YELLOW 100'

37
WD-30-R

WD-30-R

OK Industries (Jonard Tools)

WIRE WW 30AWG PVDF RED 50'

5
R26B-0100

R26B-0100

OK Industries (Jonard Tools)

WIRE WW 26AWG PVDF BLUE 100'

34
KSW30BLK-0100

KSW30BLK-0100

OK Industries (Jonard Tools)

WIRE WW 30AWG PVDF BLACK 100'

18
W28-6DU

W28-6DU

Vector Electronics & Technology, Inc.

WIRE WW 28AWG ETFE BLUE 150'

3

Wire Wrap

1. Overview

Cables, wires, and wire wrap systems are fundamental components in electrical and electronic systems, enabling power transmission, signal integrity, and mechanical protection. Wires are single conductors, while cables consist of multiple insulated wires bundled together. Wire wrap refers to a method of assembling cables using helically wound metallic or dielectric materials to enhance shielding, flexibility, or mechanical strength. These components are critical in modern technologies such as telecommunications, aerospace, automotive, and industrial automation, where reliability and performance under demanding conditions are essential.

2. Main Types and Functional Classification

TypeFunctional FeaturesApplication Examples
Coaxial CableSingle inner conductor, braided shield, dielectric insulationRF signal transmission in telecommunications
Twisted Pair CableTwisted wire pairs to reduce crosstalkEthernet networks (e.g., Cat6)
Fiber Optic CableGlass/plastic fibers for light-based data transmissionHigh-speed internet and medical imaging
Power CableThick conductors with high current capacityIndustrial machinery and grid infrastructure
Wire Wrap CableHelically wrapped metallic/dielectric shieldingAerospace sensors and high-vibration environments

3. Structure and Composition

A typical cable/wire system comprises:

  • Conductor: Copper or aluminum for electrical conductivity
  • Insulation: PVC, PE, or Teflon to prevent short circuits
  • Shielding: Braided copper, foil, or wire wrap layers to block EMI/RFI
  • Jacket: Durable polymer for mechanical and environmental protection

Wire wrap structures often use precision-wound metallic tapes or fibers to reinforce shielding and flexibility.

4. Key Technical Specifications

ParameterDescriptionImportance
Conductor Gauge (AWG)Wire thickness determining current capacityEnsures safe power transmission
Impedance ( )Resistance to AC signal flowMatches source/load for signal integrity
Operating Temperature (-55 C to +150 C)Thermal tolerance rangePrevents degradation in harsh environments
Shielding Effectiveness (dB)EMI/RFI attenuation capabilityReduces interference in sensitive systems
Bend Radius (mm)Minimum allowable cable curvaturePrevents mechanical damage during installation

5. Application Fields

  • Telecommunications: 5G base stations, undersea fiber networks
  • Automotive: EV battery harnesses, CAN bus systems
  • Aerospace: Avionics wiring, radar systems
  • Industrial: Robotics, factory automation PLCs
  • Consumer Electronics: USB cables, HDMI connectors

6. Leading Manufacturers and Products

ManufacturerRepresentative ProductKey Features
CommScopeSYSTIMAX GigaSPEEDCat8 cable for 40G Ethernet
Prysmian GroupOkonite PowerGuard138kV HV power cable
TE ConnectivityDEUTSCH DT SeriesMilitary-grade circular connectors
AmphenolOFC High-Speed FiberSingle-mode fiber for data centers
3MWire Wrap TerminalsHigh-reliability insulation displacement connectors

7. Selection Recommendations

Key considerations include:

  • Electrical requirements (voltage, frequency, signal type)
  • Environmental conditions (temperature, moisture, chemical exposure)
  • Mechanical demands (flexibility, bend radius, vibration resistance)
  • Compliance with standards (UL, ISO, MIL-SPEC)
  • Total cost of ownership (installation, maintenance, lifespan)

Example: For underwater ROV systems, select polyurethane-jacketed fiber optic cables with >50k insulation resistance.

8. Industry Trends

Emerging trends include:

  • Miniaturization for IoT and wearable devices
  • Development of halogen-free flame-retardant materials
  • Integration of smart sensors within cable jackets
  • Adoption of AI-driven cable fault diagnostics
  • Advancements in high-temperature superconducting cables
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