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PTFE INSULATED ELECTRONIC &
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 PTFE WIRES & CABLES

 WIRES PER U.S.A. MIL-W-16878
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PTFE Insulated Wires

PTFE Insulated wires and cables are divided into six sub-groups according to the construction and applications.  The common features are:

Conductors
  • Silver Plated Copper (SPC) for use up to 200°C (minimum 1 micron silver coating as per ASTM-B-298)
  • Nickel Plated Copper (NPC) up to 260°C (minimum 1.25 micron nickel coating as per ASTM-B-355)
  • Silver Plated High Strength Copper Alloy (SPHSCA) for mechanical strength in fine cross-sections and for superior flex-life (somewhat lower conductivity than copper) generally as per ASTM-B-624
  • Pure Nickel for use up beyond 260°C; very high resistance to corrosion; DC resistance about 6 times that of copper at 20°C
  • Resistance alloys for Thermo-Couple applications
  • Silver Plated Copper Clad Steel (SPCCS) commonly used for RF coaxial cables) as per ASTM-B-501
  • Spiral multi-strands on glass-fibre cord for high linear resistance -- generally for heating applications
  • Plain copper or Tinned copper can not be used due to high-temperature processing and applications; tin melts and flows into the interstices of stranding to make the conductor inflexible; copper tends to oxidize and become brittle
Sizes/Strandings
  • Single strands from 0.05 to 1.02 mm (0.002" to 0.040"), or more
  • 7, 19, 37, 61 true concentric strands, or 133 strands rope-lay (19 x 7)
  • Even AWG sizes from AWG 34 to AWG 6 (AWG 4 under development)
  • Odd AWG sizes and other type of strandings/bunchings also available
  • Integrated conductor facility ensures tighter control on resistance, diameter, finish etc.
  • For further details, please refer to size table
Insulation/Dielectricis always PTFE (Poly Tetra Fluoro Ethylene C2F4) which is the safest, cleanest, and most stable fluoro-carbon.  Click here for Properties of PTFE.  Multi-lap tape-wrapped sintered for 
  • 250 V AC RMS (so called Type ET with nominal 0.17 mm radial wall thickness in 3 layers)
  • 600 V AC RMS (Type E, 0.25 mm - 0.010" - nominal radial wall)
  • 1000 V AC RMS (Type EE, 0.38 mm - 0.015" - nominal radial wall)
  • For further details, please refer to size table
Compounded PTFE for High Voltage Cables; Sandwiched Polyimide (Kapton ®) Film for protection of PTFE from radiation. 

Colours are 10 standard electronic as per MIL-STD-104, plus shades and stripes; details here

Metal Shields/Sheaths

  • Round wire silver plated copper (SPC) or nickel plated copper (NPC)
  • SPC or Plain Copper Flat Foil 
  • SS wires
Shielding methods
  • Braided
  • Served for lower overall diameter, especially for triaxial constructions
  • Aluminised Polyester Film with drain wire (not compatible with PTFE jackets)
  • Combination of Flat foil with round wire braid or Aluminised Polyester with round wire braid
Jackets/Outer Coverings over shields are mainly of PTFE (upto 12 mm OD); larger sizes are difficult with PTFE.  PVC or Silicone Varnished Fibre Glass or Polyurethane are available for such cases (or otherwise).

Teflon ® is a DuPont Trade Mark
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