Taking advantage of TRI's six decades of experience working in areas such as high voltage induced electric fields, high dielectric strength materials and low partial discharge interconnect design to create wire products rated to up to 60 kVDC that are far superior in performance, size, mass and flexibility to what is available from the traditional wire market.  Designs and features include:
  • Single and multi-conductor designs with or without shielding and jacketing
  • High flexibility designs starting at ratings of 3kVDC with an overall diameter as small as .019" (.48mm)
  • Proprietary Ready-to-BondTM etched or silicone coated FEP and PFA to enable cohesive bonds to encapsulants without any further surface preparation of the wire by the customer
  • Distributed loss, low pass filter, RF attenuation design
  • Low partial discharge, semi-conductive layer designs      

For a technical discussion on Teledyne Reynold's high voltage wire and cable, please Download PDF

FEP High Voltage Wire

Benefits of extruded fluorinated ethylene propylene (FEP) insulated high voltage wire and cable:

  • Exceptional dielectric strength without the disadvantages common to equally rated silicone rubber insulated wire
  • Wire, cable assemblies and cable bundles have much smaller diameter than silicone wire and, therefore, take up substantially less volume while also having a smaller bend radius allowing the designer to better utilize the space within the system
  • Good corona inception qualities
  • Excellent durability and resistance to dielectric/cooling fluid degradation
  • Inert when exposed to most industrial solvents and chemicals
  • Meet NASA low outgassing TML and CVCM levels 
  • Not prone to "pin-holing" and high voltage punch-through when the cable surface is abraded or when strands break during in-field use 
  • More resistant to damage when making contact with sharp edges, although this should be avoided when designing high voltage systems

While difficult to bond to, with the use of TRI's proprietary surface preparations and coating processes, Ready-to-Bond™ versions are available that offer an excellent silastic bond.

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Nomex® is a registered trademark of Dupont

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PFA High Voltage Wire

Benefits of extruded perfluoroalkoxy (PFA) insulated high voltage wire and cable are very similar to FEP:

  • Exceptional dielectric strength without the disadvantages common to equally rated silicone rubber insulated wire 
  • Offers a higher operating temperature and has superior mechanical strength at high temperature as compared to FEP insulation 
  • Wire, cable assemblies and cable bundles have much smaller diameter than silicone wire and, therefore, take up substantially less volume while also having a smaller bend radius allowing the designer to better utilize the space within the system 
  • Good corona inception qualities 
  • Excellent durability and resistance to dielectric/cooling fluid degradation 
  • Inert when exposed to most industrial solvents and chemicals  
  • Meet NASA low outgassing TML and CVCM levels  
  • Not prone to "pin-holing" and high voltage punch-through when the cable surface is abraded or when strands break during in-field use  
  • More resistant to damage when making contact with sharp edges, although this should be avoided when designing high voltage systems

While difficult to bond to, with the use of TRI's proprietary surface preparations and coating processes, Ready-to-Bond™ versions are available that offer an excellent silastic bond.

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PTFE and ETFE High Voltage Wire

Benefits of extruded ethylene tetrafluoroethylene (ETFE) and polytetrafluoroethylene (PTFE) insulated high voltage wire and cable are very similar to FEP:

  • High dielectric strength 
  • Excellent high temperature properties 
  • Excellent chemical resistance   
  • Resist moisture obsorption

    While difficult to bond to, with the use of TRI's proprietary surface preparations and coating processes, R​eady-to-Bond™ versions are available that offer an excellent silastic bond.

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    Silicone Rubber High Voltage Wire

    Silicone rubber insulated high voltage wire and cable offer excellent dielectric strength and flexibility. Operation over a wide temperature range and ease of silastic bonding are other outstanding characteristics of silicone rubber cable.

    Due to the relatively softer nature of silicone insulation, when compared to other insulation materials, these wires are more susceptible to “pin-hole” breakdown, abrasion, and some dielectric/coolant fluid incapabilities exist.

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    High Voltage Coaxial/Shield Wire

    Coaxial and shielded cables made by Teledyne Reynolds have been used in space, military, medical and industrial high voltage applications including radar, electronic countermeasure (ECM) systems, power supplies and instrumentation. Many of the cables have controlled impedance.

    For example, part numbers 167-2669 and 178-8793 have controlled impedance, inductance and capacitance for fast response times and are used extensively to connect Exploding Bridgewire Detonators (EBW) to Capacitor Discharge Units (CDU). For applications that require a low capacitance and high impedance high voltage coax, a part number like 178-5065 with foam insulation would be ideal.

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    Micro FlexTM High Flexibilty, High Voltage Wire

    Teledyne Reynolds has developed a range of highly flexible high voltage wires that are particularly suitable to the aircraft environment. The technology is a direct result of TRI's research into durable and flexible cable assemblies needed for Helmet Mounted Display (HMD) systems. These wires have a PFA insulation and high strand count of silver plated copper conductors that enable the wire to have high tolerance to work hardening. They have been designed to operate over a wide temperature range of -55° to 125°C at their rated voltages and at altitudes up to 70,000 feet (21,336 meters). Micro FlexTM is available as single wire, twisted pairs or as multi-core cable with or without shielding.

    While PFA is difficult to bond to, with the use of TRI's proprietary surface preparations and coating processes, Ready-to-Bond™ versions are available that offer an excellent silastic bond.

    Teledyne Reynolds’ unique capability to manufacture Micro FlexTM cable bundles involves the use of special winding tooling to take advantage of the flexibility of the individual wire when laying up a bundle.

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    Quiet LineTM High Voltage Distributed Loss, RF Attenuation Wire

    Quiet LineTM is a continuously extruded, distributed loss, low-pass filter wire for use in high voltage applications. The stranded center conductor is surrounded with a “lossy” insulation material comprised of ferrite-powder filled silicone. This cable functions much like an inductive low-pass filter, where magnetic losses are dissipated and EMI absorbed. The ferrite in the insulation increases the cable’s inductance by concentrating the magnetic field. The increase in inductance, in turn, increases reactance which filters out high frequency noise. The cable’s attenuation characteristics increase with frequency and are directly proportional to cable length.

    TRI’s Quiet LineTM is excellent for use in any high frequency, high voltage application requiring the suppression of undesired RF interference or EMI noise. In addition, use of Quiet LineTM alleviates the need for a traditional low-pass filter circuit with standalone inductors and resistors that increase the mass and take up volume in the system. These attributes make Quiet LineTM an ideal solution in radar, telecommunications and electronic countermeasures. Other applications include filtering capacitive or inductive coupled noise.

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    Semi/ConTM, Semi-Conductive, Silicone Rubber High Voltage Wire

    Semi/ConTM high voltage, semi-conductive silicone cables have a distinct advantage over standard high voltage cables in that they are more resistant to electrical stress and exhibit very little to no corona at the rated voltage.

    Corona is an ionization of gas molecules that occur in voids of a cable and along the outside of the cable insulation when near a ground plane. The damage to the wire insulation from corona is proportional to the number of discharges per unit time and the energy of each discharge. Reducing or eliminating these discharges, commonly referred to as partial discharge, should be a design goal in any high voltage system design. Standard high voltage cables are very reliable in service when installed in equipment and physically separated from grounded structures, especially sharp edges. When these requirements cannot be met or the voltage is pulsed DC or AC, and the need is still present for a high voltage cable that exhibits little to no corona discharge, along with a long operating life, Semi/ConTM cable is the solution.

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