Wire Wrap

Image Part Number Description / PDF Quantity Rfq
W28-6H

W28-6H

Vector Electronics & Technology, Inc.

WIRE WW 28AWG ETFE BLACK 50'

0

W28-6HU

W28-6HU

Vector Electronics & Technology, Inc.

WIRE WW 28AWG ETFE BLACK 150'

3

W28-6BU

W28-6BU

Vector Electronics & Technology, Inc.

WIRE WW 28AWG ETFE RED 150'

75

W28-6A

W28-6A

Vector Electronics & Technology, Inc.

WIRE WW 28AWG ETFE GRN 50' 2/PK

3

W28-6DU

W28-6DU

Vector Electronics & Technology, Inc.

WIRE WW 28AWG ETFE BLUE 150'

3

W28-6AU

W28-6AU

Vector Electronics & Technology, Inc.

WIRE WW 28AWG ETFE GREEN 150'

0

W28-6D

W28-6D

Vector Electronics & Technology, Inc.

WIRE WW 28AWG ETFE BLUE 50'

0

W28-6FU

W28-6FU

Vector Electronics & Technology, Inc.

WIRE WW 28AWG ETFE YELLOW 150'

3

W28-6EU

W28-6EU

Vector Electronics & Technology, Inc.

WIRE WW 28AWG ETFE WHITE 150'

15

W28-6B

W28-6B

Vector Electronics & Technology, Inc.

WIRE WW 28AWG ETFE RED 50'

0

W28-6E

W28-6E

Vector Electronics & Technology, Inc.

WIRE WW 28AWG ETFE WHITE 50'

0

W28-6F

W28-6F

Vector Electronics & Technology, Inc.

WIRE WW 28AWG ETFE YELLOW 50'

0

W30-5AS

W30-5AS

Vector Electronics & Technology, Inc.

WIRE WW 30AWG PVDF GREEN 300'

0

W30-5B

W30-5B

Vector Electronics & Technology, Inc.

WIRE WW 30AWG PVDF RED 75'

0

W30-5FS

W30-5FS

Vector Electronics & Technology, Inc.

WIRE WW 30AWG PVDF YELLOW 300'

0

W30-5F

W30-5F

Vector Electronics & Technology, Inc.

WIRE WW 30AWG PVDF YELLOW 75'

0

W30-5A

W30-5A

Vector Electronics & Technology, Inc.

WIRE WW 30AWG PVDF GREEN 75'

0

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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