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Micro Flex Wire and Cable

Reynolds has developed a range of highly flexible cables that are particularly suitable to the aircraft environment. This technology is a direct result of our research into durable and flexible cable assemblies needed for Helmet Mounted Display (HMD) systems. The wire utilized in these cable assemblies has a PFA insulation and all of the conductors are high strand count silver plated copper. They are durable and have excellent tolerance to work hardening environments. They have been designed to operate over a wide temperature range of -55°C to +125°C at their rated voltages and at altitudes up to 70,000 feet (21,000) meters). Micro Flex is available as single wire, twisted pairs or as multicore cable with or without shielding.

Reynolds unique capability to manufacture Micro Flex cable includes special winding tooling to take advantage of the flexibility of the individual cables in laying up a multi-cable bundle.
Features
  • Flexible
  • Up to 18 KVDC operation
  • PFA insulation
  • Small and lightweight
  • Durable
  • Reliable
  • Non-combustible, low smoke rating
  • -55°C to +125°C temperature rating
Micro Flex Testing
 The following tests have been performed to MIL-W-22759 Guidelines:
• Wrap test• Life cycle• Low temperature (cold bend)
• Insulation resistance• Bend test• Thermal shock
• Blocking• Dielectric test• Humidity
Typical Applications
 
• HMD CRT Cabling• Helmet tracker cabling
• Ejection safe QDC cabling• Medical instrumentation cabling
• Communication cabling• High vibration aircraft cabling
• NVG ejection cabling• Flight line or automotive test equipment cabling

 

Low Voltage Micro Flex Wire and Cable
Operating Voltage: 250 volts DC . 100% tested at 2000 volts DC wet spark
Sample tested at 1500 volts DC at simulated 70,000 foot altitude
Unshielded
Conductor
PlatingConductorØ Over InsulationPart
Number
AWGStrandsØ In./ mmIn./MM
3041/46SPC.012/0.30.018/0.46178-5125
2951/46SPC.013/0.35.019/0.48178-5126
2841/44SPC.014/0.37.022/0.56178-5127
2841/44SPC.014/0.37.032/0.81178-5109
2666/44SPC.018/0.48.025/0.64178-5128
2666/44SPC.018/0.48.032/0.81178-5110
2441/40SPC.023/0.59.035/0.89178-5129
2265/40SPC.030/0.78.041/1.04178-5130
20105/40SPC.039/0.99.054/1.37178-5131

Shielded
Conductor
PlatingConductorØ Over InsulationØ Over BraidPart
Number
AWGStrandsØ In./ mmIn./MMIn./MM
2841/44SPC.014/0.37.032/0.81.044/1.12178-5108
2441/40SPC.023/0.590.35/0.89.049/1.25178-5518
2265/40SPC.030/0.78.041/1.04.053/1.35178-5318


 
 
Construction
Part Number
Twisted Pair
2 X 178-5109 Blue
2 X 178-5110 Green
178-5515
178-5517
Shielded Twisted Pair
2 X 178-5109 Blue
178-5516
Shielded Twisted Quad
4 X 178-5109 Blue
178-5111

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High Voltage Micro-Flex Wire and Cable
High Voltage Micro-Flex
Micro Flex wire and cable, like FEP high voltage wire and cable, is available uncoated or with a silicone rubber coating over the PFA insulation. The coated cable is processed with a silicone rubber coating continuously applied to the etched surface of the cable. The coated cable has characteristics similar to silicone rubber cable and a superior dielectric bond to silicone rubber potting or bonding material can be achieved.
High Voltage Micro-Flex Attributes
Operating Voltage (KVDC)
Conductor
PlatingConductorØ Over InsulationPart
Number
AWGStrandsØ In./ mmIn./MM
32951/46SPC.012/0.33.019/0.48 178-5132
52951/46SPC.012/0.33.025/0.64 178-5135
13.52841/44SPC.014/0.37.042/1.07 178-5138
182441/40SPC.022/0.58.050/1.27 178-5141
251641/32SPC.059/1.50.125/3.17178-5577

Silicone Coated High Voltage Micro-Flex Attributes
Operating Voltage (KVDC)
Conductor
PlatingConductorØ Over InsulationPart
Number
AWGStrandsØ In./ mmIn./MM
32951/46SPC.012/0.33.029/0.79178-5134
52951/46SPC.012/0.33.035/0.89178-5137
13.52841/44SPC.014/0.37.052/1.32178-5140
182441/40SPC.022/0.58.060/1.52178-5143

Shielded High Voltage Micro-Flex Attributes
Operating Voltage (KVDC)
Conductor
PlatingConductorØ Over InsulationØ Over BraidPart
Number
AWGStrandsØ In./ mmIn./MMIn./MM
62265/40SPC.030/0.76.041/1.04.053/1.35178-5459-00
62265/40SPC.030/0.76.041/1.04.053/1.35178-5459-01
62265/40SPC.030/0.76.041/1.04.053/1.35178-5459-02
62265/40SPC.030/0.76.041/1.04.053/1.35178-5459-03
62265/40SPC.030/0.76.041/1.04.053/1.35178-5459-04
62265/40SPC.030/0.76.041/1.04.053/1.35178-5459-05
62265/40SPC.030/0.76.041/1.04.053/1.35178-5459-06
62265/40SPC.030/0.76.041/1.04.053/1.35178-5459-07
62265/40SPC.030/0.76.041/1.04.053/1.35178-5459-08
62265/40SPC.030/0.76.041/1.04.053/1.35178-5459-09
62265/40SPC.030/0.76.041/1.04.053/1.35178-5459-10
To specify acolor add a hyphen to the Part Number as follows:
-00 Black -01 Brown -02 Red -03 Orange -04 Yellow -05 Green -06 Blue -07 Violet -08 Gray -09 White -10 Natural 
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HI/Bus High Voltage Bus Line
HI/Bus - High Voltage Line
An insulated high voltage bus bar for use in densely populated high voltage power supplies. HI/Bus can be bent and will retain its shape prior to soldering and potting. Hi/Bus is rated at 5 KVDC for altitudes up to 70,000 feet (21,000 m)

HI/Bus can be ordered with a silicone coating over the PFA insulation which provides the user with a compatible surface to bond or encapsulate using silicone rubber potting material. The coated surface should be primed in accordance with the instructions of the manufacturer of the potting material.
HI/Bus Advantages
  • Easily formed
  • Silver plated solid copper conductor
  • Available on spools
  • Color options
  • Optional silicone rubber coating
Hi/Bus - High Voltage Bus Line Attributes
Operating Voltage (KVDC)
Conductor
Conductor
Ø In./ mm
Silicone
Coating
OverallPart
Number
Solid SPC
AWG
Ø In./MM
530.010/0.25NO.021/0.53178-5207
526.016/0.41NO.027/0.69178-5208
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"Quiet Line" Distributed Loss R.F. Attenuation Line
Quiet Line is a continuously extruded, distributed loss, low pass filter line
for high voltage applications. Quiet line is a flexible element offering R.F. power attenuation and can be spliced onto an existing high voltage lead assembly or supplied as an entire high voltage lead assembly.

Quiet Line is available with or without a silicone rubber coating. This continuous thin wall coating is applied over the FEP or PFA jacket and allows the user to achieve a superior dielectric bond when potting or encapsulating with a compatible silicone material.

Quiet Line is available either shielded or non-shielded with or without the silicone rubber coating. Six loss core diameters are offered providing a range of rated voltages and R.F. insertion loss characteristics. The configurations are shown on page 15 and the attributes of each configuration.

Special configurations are available pending a review of your requirements by Reynolds engineering department personnel.
General Specifications
Conductor and braid:Copper, silver plated
Insulation :Extruded PFA (fluorocarbon)
Jacket:PFA or FEP
Operating Temperature:-55°C through +125°C at 70,000 foot altitude
Voltage stress testing:100% test at 140% of rated voltage (room ambient)
Insertion loss testing:100% insertion loss verification performed on each extrusion lot. The swept frequency insertion loss technique is used within the specified frequency range per MIL-C-17F. Test specimens are shielded with a BNC termination.

"Quiet Line" Attributes

Operating
Voltage (KVDC)
Attenuation
dB/Ft (Nom)
Inner Conductor SPCFigure 1Figure 2Figure 3Figure 4Figure 5
480mhz2.4ghzAWGStrandsP/NDia.
in./mm
P/NDia.
in./mm
P/NDia.
in./mm
P/NDia.
in./mm
P/NDia.
in./mm
1211902219/34178-8051.085/2.1178-8024.095/2.4178-8069.135/3.3178-8064.145/3.6178-8306.155/3.9
1515602419/36178-8301.073/1.8178-8302.080/.20      
20211402219/34178-8053.150/3.8178-7968.160/4.0      
20211302219/34178-8050.130/3.3178-8025.140/3.5  178-8063.200/5.0  
2015902219/34178-8382.110/2.7178-8381.120/3.0  178-8337.170/4.3  
20211302019/32178-8253.140/3.5178-8254.150/3.8  178-8265.200/5.0  
20211302019/32178-8054.150/3.8178-7953.160/4.0178-8772.250/6.3    
20211302219/34178-8104.140/3.5178-8105.150/3.81  178-8106.195/4.9  
20211302219/34178-8055.150/3.8178-7952.160/4.0      
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Cable Conductor Data Size - Stranding - Current Rating
 
AWGStrandingApprox DiameterCross SectionDC ResistanceCurrent Raiting
mminchesmm^2Ohms/1000m(amps) free air. 80º C*
3041/460.30.0120.051337.30.4
2951/460.350.0140.064271.30.5
2841/440.370.0140.064271.30.5
26SOLID0.40.0160.13133.91
26111390.480.0190.141122.41
26119620.510.020.13136.21
2619/380.50.020.151113.81
2651/420.560.0220.16107.31
2666/440.480.0190.131131.91
24SOLID0.510.020.20584.31.6
24104090.61.O240.22476.81.6
24112310.640.0250.20185.61.6
2416/360.610.0240.201851.6
2419/360.640.0250.24171.51.6
2441/400.590.0230.205841.6
22SOLID0.640.0250.32652.82.5
22349090.760.030.35648.22.5
2219/340.80.0320.38344.92.5
2226/360.750.030.32952.52.5
2265/400.780.0310.32652.52.5
20SOLID0.810.0320.51833.54
20349070.960.0380.56730.54
20350011.020.040.50933.84
2019/321.010.040.60928.24
2026/340.940.0370.52432.84
20105/400.990.0390.52632.84
18SOLID1.020.040.823214
18349051.210.0480.901194
1816/301.230.0480.815214
1819/301.270.050.96817.74
1841/341.190.0470.826214
1865/361.250.0490.823214
18168/401.340.0530.84220.34
16SOLID1.290.0511.30914.110
16349031.530.061.43312.110
1619/291.430.0561.2214.110
1626/301.50.0591.2214.110
1641/321.50.0591.32613.310
1665/341.570.0621.30913.110
16260/401.730.0681.30313.110
14SOLID1.630.0642.0818.215
14349011.850.0732.2857.615
1419/271.80.0711.948.915
1441/301.890.0752.0888.215
12348992.440.0963.664.920
1219/252.270.093.0855.620

*Please refer to Mil-W-5088 for specfic current ratings
Index by Part Number

167-2669
167-2896

167-7628
167-8556
167-8653
167-8726
167-9169
167-9180
167-9193

167-9346
167-9470
167-9596

167-9611
167-9634
167-9785
178-5065
178-5079
178-5108
178-5109
178-5110
178-5111
178-5125
178-5126
178-5127
178-5128
178-5129
178-5130
178-5131

178-5132
178-5134
178-5135
178-5137

 
178-5138
178-5140
178-5141
178-5143

178-5186
178-5207
178-5208

178-5318
178-5515
178-5516
178-5517
178-5518

178-5546
178-5459
178-5577

178-5597
178-5626
178-5627
178-5724
178-5789

178-5790
178-5792

178-6109
178-7200
178-7201
178-7221

178-7435
178-7680

178-7952
178-7953
178-7968
178-8024

 
178-8025
178-8050
178-8051
178-8053
178-8054
178-8055
178-8063
178-8064

178-8066
178-8067

178-8069
178-8072
178-8073

178-8074
178-8104
178-8105
178-8106
178-8253
178-8254
178-8265
178-8301
178-8302
178-8306

178-8315
178-8316
178-8337
178-8381
178-8382

178-8523
178-8545
178-8679
178-8751

 
178-8772
178-8781
178-8881
178-8883
178-8884
178-9036
178-9277
178-9334

178-9490
178-9554
178-9560
178-9578
178-9824
178-9907
178-9912

 


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上次更新日期: 2016年04月13日。