Cable, Mr. Right. ——Said by PCBA.
♩ Material engineering view
“Signal runs on copper is function; signal runs safely and stably under various environments is performance.” As a senior cable chief engineer said: “Copper is the skeleton, material is the soul. Good wire sells not copper, but formula.”
From the application perspective of insulation material engineering, we provide customized wires. The six‑dimensional balance of insulation material engineering:
♪ Conductor coating (tin, silver, nickel)
♫ Application decision tree
Q1: working temp ≥120°C long term?
✅ Yes → exclude tin (alloying >120°C, solderability lost >150°C).
♪ HF/low R Silver + FEP/PTFE
♪ high temp only Nickel + silicone/PFA
❌ No (≤105°C) → go to Q2
Q2: signal integrity >100MHz or ultra‑low contact R?
✅ Yes → Silver (skin effect advantage)
❌ No (DC/low freq) → go to Q3
Q3: severe chemical corrosion (sulfide, acid) or extreme shelf life?
✅ Yes → Nickel (or Ni+thin Au/Ag)
❌ No (indoor normal) → Tin — most suitable, low cost, mature supply.
♪ Insulation jacket – "technology value hill"
Insulation determines where, how long, how fast, how safe the wire can be used.
♩ Electrical
PVC (Dk≈3.5) → PE/PP (2.3) → FEP/PTFE (2.1) → foamed PE/fluoroplastic (<1.5). EV high‑speed data needs foamed PE/fluoroplastic.
♪ Thermal
PVC 80-105°C / XLPE 125-150°C / silicone 150-200°C / fluoroplastic 200-260°C. 18AWG PVC→3A, PFA→10A.
♫ Environmental
PVC fails at >100°C, -40°C brittle, UV, oil; FEP/silicone, ETFE/TPU, XLPE/TPU, ETFE/FEP solve each. PV cable needs XLPO/fluoroplastic.
♬ Mechanical
Flex: silicone/TPE; abrasion: TPU/ETFE (robot); tear: cross‑linked. (Wear → replace PVC with ETFE)
♭ Safety/environmental
Flame VW‑1/FT1; halogen‑free (no PVC); RoHS/REACH. (EU rail/marine → halogen‑free XLPO or fluoroplastic)
♩ Wire data index
Complete translation of your “wire data.xlsx” – all categories listed below with ♪ bullets.
♪ Master table ♪
♩ copper is skeleton, formula is soul ♩
