Braided Silicone Insulated Wires are high-performance electrical cables known for their flexibility, durability, and heat resistance. Featuring a silicone rubber insulation with braided copper conductors, they're ideal for demanding applications in industries like aerospace, automotive, and electronics.
Operating Temperature: -60°C to + 200°C
Operating Voltage: 600V
Insulation: silicon rubber
Approval: UL
Operating Temperature: -60°C to + 200°C
Operating Voltage: 600V
Insulation: silicon rubber
Approval: UL
Operating Temperature: -60°C to + 200°C
Operating Voltage: 300V
Insulation: silicon rubber
Approval: UL
1. Conductor:
The conductor is the core component of the wire responsible for carrying electrical current from one point to another. Common materials used for conductors in braided silicone insulated wires include:
Copper: Copper is the most common conductor material due to its excellent conductivity and flexibility. It can be either solid or stranded (multiple smaller strands twisted together), offering different levels of flexibility and durability.
Tinned Copper: Tinned copper conductors are copper wires coated with a thin layer of tin, which improves corrosion resistance and solderability.
2. Silicone Insulation:
The conductor is surrounded by a layer of silicone rubber insulation, which provides electrical insulation and thermal resistance. Silicone insulation offers the following properties:
High Temperature Resistance: Silicone rubber can withstand elevated temperatures, typically up to 200°C or higher, making it suitable for applications in hot environments such as automotive engine compartments and industrial machinery.
Flexibility: Despite its high-temperature resistance, silicone insulation remains flexible and pliable, facilitating easy installation and routing in tight spaces.
Electrical Properties: Silicone rubber maintains excellent electrical properties, including high dielectric strength, insulation resistance, and low capacitance, ensuring reliable electrical performance.
Chemical Resistance: Silicone insulation is resistant to oils, solvents, chemicals, and environmental factors, enhancing the durability and lifespan of the wire.
3. Braided Shielding:
Surrounding the silicone insulation is a braided shielding layer made of conductive material, typically tinned copper, woven in a mesh-like pattern around the insulated conductor. The braided shield serves several purposes:
Mechanical Protection: The braided shield provides protection against abrasion, impact, and mechanical stress, reducing the risk of damage to the underlying insulation.
Electromagnetic Interference (EMI) Shielding: The braided shield acts as a barrier against electromagnetic interference (EMI) and radio frequency interference (RFI), minimizing signal interference in sensitive electronic applications.
Enhanced Durability: The braided shielding layer improves the overall durability and resistance to external environmental factors, ensuring reliable performance in harsh conditions.
4. Additional Components (Optional):
Depending on the specific application and requirements, braided silicone insulated wires may include additional components such as:
Jacketing: An outer protective jacket or sheath may be applied over the braided shielding layer to provide further protection against moisture, chemicals, and physical damage.
Color Coding: Different colors of insulation or marking stripes may be used to identify individual wires within a cable assembly, facilitating installation and maintenance.
Role of Braided Shielding:
Braided silicone wires feature a conductive braided shield surrounding the silicone insulation and conductor. This shield acts as a barrier against electromagnetic interference (EMI) and radio frequency interference (RFI) from external sources.
Shielding Effectiveness:
The braided shield provides a path for dissipating and redirecting electromagnetic fields away from the internal conductors. This helps prevent interference that can degrade signal quality or cause electrical noise.
Shielding Material and Construction:
The braided shield is typically made of tinned copper or other conductive materials woven into a mesh-like pattern around the insulated conductor. This construction ensures good coverage and continuity of the shielding layer.
Frequency Range:
Braided silicone wires are effective across a broad range of frequencies, including both lower-frequency noise from power lines and higher-frequency noise from electronic devices.
Protection Against External EMI Sources:
The shielding provided by braided silicone wires helps protect sensitive electronic components and circuits from external EMI sources, such as nearby power cables, motors, or radio transmitters.
Reduction of Signal Distortion:
EMI shielding minimizes signal distortion and attenuation caused by electromagnetic interference. This is crucial for maintaining the integrity of analog and digital signals in communication and data transmission applications.
High-Frequency Applications:
Braided silicone wires are suitable for high-frequency applications where signal integrity is critical, such as in telecommunications, aerospace, and medical equipment.
Low Noise and Cross-Talk:
Effective EMI shielding reduces electrical noise and cross-talk between adjacent wires, ensuring clean and reliable signal transmission.
Compliance with Industry Standards:
Braided silicone wires are designed to meet specific industry standards for EMI shielding effectiveness, ensuring compliance with regulatory requirements and performance specifications.
Installation and Routing:
Proper installation practices, including minimizing wire lengths and avoiding parallel runs with high-power cables, can help reduce the risk of EMI.
Connector and Termination Quality:
High-quality connectors and terminations are essential for maintaining EMI shielding integrity and minimizing signal loss at connection points.
Testing and Validation:
Conducting EMI testing and validation during product development ensures that braided silicone wires meet performance requirements and provide adequate EMI protection.
