Design Considerations

Design ConsiderationsFor power distribution applications that require high temperature wire with maximum flexibility, New England Wire Technologies has single and multiconductor cables available in sizes up to 250 MCM. Our flexible interconnects are commonly supplied in UL and CSA recognized PVC insulated constructions, but these conductors can also be insulated with silicone rubbers, polyester, polyurethanes or TPEs.

In addition, New England Wire Technologies has developed special-use, proprietary power cables. Hyflex™ Power Distribution cables are specifically engineered to handle the high voltage and temperatures inherent with today’s diesel hybrid vehicles. Independently tested to meet the requirements of SAE J 1654 and 1127, Hyflex™ cables are rated for use at 125˚ C and up to 600 volts.

COLDflex Ground Cables™ were developed using a high performance compound specifically formulated for flexibility in power distribution applications during cold weather…down to –40˚ C, is UV resistant and has an operating voltage up to 5kV.


Design Considerations for Custom Flexible Interconnects

  • High Temperature
    • Conductors
      • Silver Plated  Copper – UL Rated to 200°C
      • Nickel Plated Copper –  Rated up to 450°C
    • Insulation Materials
    • FEP (Fluoropolymer) – 200°C
    • PFA (Fluoropolymer) – 250°C
    • Silicone Rubber – 200°C
  • Low Temperature
    • Fluoropolymer – Cryogenic
    • Silicone Rubber – Cryogenic
    • Polyurethane -50°C
  • Chemical Resistance
    • Fluoropolymer
    • Polyester
    • Nylon
  • Voltage
    • Fluoropolymer – Excellent Dielectric Strength
    • Silicone Rubber – Resistant to Corona breakdown in high voltage AC applications
  • Low Capacitance
    • Fluoropolymer (2.03 – 2.08 Dielectric Constant)
    • Polyethylene (2.28 – 2.32 Dielectric Constant)
  • Flexibility
    • PVC – Good Flexibility, modest cut through and tear resistance
    • Silicone Rubber – Excellent flexibility, poor mechanical properties
    • Thermoplastic Elastomers – Improved flexibility over PVC, with better mechanical properties than Silicone

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