In high-end applications such as aviation, aerospace, weapons, and ships, electrical wiring connections face multiple challenges, including extreme temperature fluctuations, strong radiation, chemical corrosion, and tight installation spaces. Traditional cables often fail due to insufficient temperature resistance, excessive size, or insufficient protective performance. TST CABLE’s THAK-200 halogen-free, high-temperature, and high-strength single-core cable features a silver-coated copper core and polyetheretherketone (PEEK) insulation. It combines multiple advantages, including halogen-free flame retardancy, ultra-lightweight and compact design, and wide temperature tolerance. It precisely meets the electrical connection requirements of high-end equipment and provides a reliable guarantee for line safety in extreme environments. PEEK Low-Smoke Zero-Halogen Insulated Single-Core Cable Core Structure
Material Innovation Lays the Foundation for High-End Performance
The superior performance of the TST CABLE THAK-200 cable stems from its scientific structural design and high-end material selection. From the conductor to the insulation, the cable is engineered to deliver high-temperature resistance, low loss, and superior protection. The specific structural and material characteristics are as follows:
Structural Layers Material Selection Core Functions and Advantages
Conductor
Silver-Plated
Copper Core 1. High Conductivity: The pure copper core ensures low-resistance transmission, meeting the high-precision power and signal transmission requirements of equipment.
- Silver-Plated Protection: The silver coating effectively resists oxidation and chemical corrosion, extending the conductor’s service life while reducing contact resistance.
- Flexibility: The multi-strand twisted structure enhances cable flexibility, making it suitable for complex internal wiring and curved installation scenarios. Insulation Layer: Polyetheretherketone (PEEK). 1. Extreme Temperature Resistance: Long-term temperature resistance ranges from -50°C to 200°C, and can withstand higher temperatures in the short term without softening or cracking, making it suitable for applications such as aircraft engine peripheries and high-temperature ship compartments.
- High Strength and Fatigue Resistance: PEEK material exhibits excellent mechanical strength and fatigue resistance, making the insulation layer resistant to damage under long-term vibration or tensile conditions, ensuring electrical insulation reliability.
- Chemical Resistance: Excellent resistance to fuel, hydraulic oil, acids and alkalis, making it suitable for the complex chemical environments of weapons and ships.
- Halogen-Free and Environmentally Friendly: Halogen-free, low-smoke, and non-toxic combustion meet the safety and environmental requirements of the aerospace industry.
Product Features of PEEK Low-Smoke Zero-Halogen Insulated Single-Core Cable
Multi-Dimensional Breakthroughs Meet High-End Application Requirements
Leveraging its structural and material advantages, the TST CABLE THAK-200 cable excels in electrical performance, environmental adaptability, and installation flexibility, fully meeting the stringent standards of aviation and aerospace applications:
- Stable Electrical Performance, Suitable for High-Precision Transmission
Wide Rated Voltage Coverage: Available in 250V and 600V rated voltages, it can accommodate both internal instrument signal lines (low voltage) and electrical equipment power lines (higher voltage), enabling diverse applications without changing cable types.
Low Transmission Loss: The silver-plated copper core conductor boasts a conductivity of over 98%, combined with the low dielectric loss characteristics of the PEEK insulation (tanδ < 0.002), ensuring low signal distortion during transmission. This makes it particularly suitable for the high-precision control signal transmission requirements of aerospace equipment. Strong Environmental Adaptability, Withstanding Extreme Operating Conditions
Stable Operation over a Wide Temperature Range: Withstands temperatures from -50°C (polar regions or high-altitude low-temperature environments) to 200°C (engine compartments and areas surrounding high-temperature equipment), it maintains insulation and mechanical strength even under extreme temperature fluctuations, showing no degradation.
Nuclear Radiation Resistance: Tests have shown no cracking in the cable insulation and no significant change in conductivity even after exposure to a gamma-ray dose of 10⁶Gy, making it suitable for the radiation environments of weapons and nuclear equipment.
Halogen-Free, Flame-Retardant, and Low-Smoke: Complies with international halogen-free flame-retardant standards (such as UL94 V-0), producing low smoke density (transmittance >80%) and no toxic halogen gas emissions during combustion. This allows for valuable time to evacuate personnel and protect equipment in confined spaces such as aircraft and ships.
High Abrasion Resistance: The PEEK insulation layer boasts a surface hardness exceeding Shore D85, making it resistant to wear from prolonged friction with equipment components or mechanical impact, reducing the risk of short circuits caused by insulation damage.
- Flexible Installation, Adaptable to Complex Spaces and Special Needs
Ultra-Lightweight and Compact Design: The combination of thin-wall PEEK insulation and a fine-diameter silver-plated copper core reduces the cable’s outer diameter by over 30% and its weight by 25% compared to traditional high-temperature-resistant cables. This cable is particularly well-suited for the lightweight and miniaturized design requirements of aviation and aerospace equipment, reducing the overall load on the equipment.
Excellent Bend Performance: The bend radius is only 10 times the cable’s outer diameter (10D), enabling multi-angle bending and routing within confined spaces within equipment, and conforming to complex structures without excessive strain.
Suitable for Stretch Installation: The PEEK insulation boasts a tensile strength exceeding 90 MPa, and the conductor stranding structure offers considerable ductility. This makes it particularly suitable for applications requiring stretch installation, such as near aircraft engine pipelines and on moving parts of ships. It maintains structural integrity and electrical performance even after prolonged stretching.
Applications of PEEK Low-Smoke, Halogen-Free Insulated Single-Core Cables
Focusing on Core Line Connections for High-End Equipment
TST CABLE THAK-200 Due to its strong adaptability to extreme environments, this cable has become the preferred connection solution for high-end fields such as aviation, aerospace, weapons, and ships. Specific application scenarios are as follows:
Aviation: Used in engine control systems, cockpit instrument connections, and landing gear electrical wiring for fighter jets and civilian airliners. It withstands high engine radiation and low altitude temperatures, while meeting the cabin’s halogen-free flame-retardant requirements.
Aerospace: Suitable for attitude control systems and payload power supply circuits for satellites and launch vehicles. It withstands the extreme temperature fluctuations (-50°C to 200°C) and cosmic radiation in the vacuum of space, ensuring stable on-orbit operation of spacecraft.
Weapons: Used in fire control systems and communication equipment connections for tanks and armored vehicles. It withstands outdoor dust, vibration, shock, and chemical corrosion, and is resistant to nuclear radiation, making it suitable for complex combat environments.
Shipbuilding: Used in power compartment electrical wiring, radar system connections, and instrument wiring in enclosed compartments. It withstands seawater salt spray corrosion, cabin temperatures, and wave impact. Its halogen-free and low-smoke properties also meet ship fire safety standards.
Standard Guarantee: Dual Endorsement of Compliance and Reliability
THAK-200 cables are manufactured and tested in strict accordance with the company standard Q/TSTGW007. This standard references high-end aerospace industry standards (such as GJB 773A and MIL-DTL-24643) for electrical performance, environmental resistance, and mechanical properties. This ensures that every batch of cables passes the following rigorous tests:
Electrical Performance Testing: Insulation Resistance (≥10¹⁴Ω・cm), Withstand Voltage (1500V/1min for 250V, 2500V/1min for 600V), and Dielectric Dissipation Test;
Environmental Testing: High and Low Temperature Cycle Test (-50°C to 200°C, 50 cycles), Salt Spray Test (5% NaCl Solution, 96 hours), Nuclear Radiation Test, and Flame Retardancy and Low Smoke Test;
Mechanical Performance Testing: Tensile Test, Bend Test (10D Bend Radius, 100 cycles), Abrasion Test (5N Load, 1000 Frictions) times).
Through standardized production and comprehensive testing, TST CABLE THAK-200 cables achieve a batch qualification rate exceeding 99.5%, providing stable and reliable quality assurance for the electrical connections of high-end equipment.
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