Task

Our customer required a cable in which 4 AWG 20 power wires are located next to two CAT5 pairs AWG 24. The line is installed into moving measuring instruments and is installed with minimum bending radii. Use is in automotive applications, the cable must be halogen free and flame resistant according to UL VW1 and withstand temperatures of 125 ° C for up to 3000 hours.

Technical challenge

To protect the measuring signals the CAT5 pairs need to be shielded. The cable must have a high level of flexibility for its installation and usage. Additionally the signal quality must be protected here as well. Due to the harsh areas of operation the cable jacket has to be very stable, even though the stipulated diameter prevents a large wall thickness.

Solution

Insulation and jacket materials are adapted to both the electrical requirements and the application temperature. As an outer jacket we chose the mechanically very resilient and abrasion-resistant TPE-V in a special version. This not only ensures that the cable is halogen free, but also guarantees the required flame resistance and assures that the required diameter of max.8.0mm is met! Following the production we carried out and documented the fire test. During the test period there were no drops from the plastic and the height of the flame did not reach the flag.