#industrialcables

Reliable Wire Supplier in Singapore for Quality Electrical & Industrial Solutions

Electrical systems in industrial environments often face exposure to oil, water, chemicals, and other harsh conditions. That’s why flexible cables from Capital Cables are designed to deliver reliable performance even in demanding situations.

With durable construction and resistance to oil, petrol, acids, and grease, these cables help maintain safe and efficient operations in factories, machinery, and heavy-duty applications.

Silicone Fiberglass Insulated Multicore Cables

In the landscape of modern industrial manufacturing, electrical connectivity is often the silent backbone of critical operations. However, in environments defined by extreme thermal stress, mechanical abrasion, and chemical exposure, standard PVC or even basic rubber-insulated cables fail rapidly. The Silicone Fiberglass Insulated Multicore Cable  represents a specialized engineering solution designed to bridge the gap between high-performance dielectric properties and rugged physical durability.

 The Architecture of Thermal Resilience

The structural integrity of a multicore silicone fiberglass cable is built from the inside out, utilizing materials that operate synchronously to maintain electrical continuity under duress.

1. Conductive Core: The Foundation

The process begins with the conductor, typically consisting of Class 5 flexible stranded copper. In high-temperature applications, bare copper is rarely used because it oxidizes rapidly above 100°C. To combat this, the strands are usually Tinned Copper or, for higher-tier specifications, Nickel-Plated Copper. Tinning provides a protective barrier against corrosion and ensures that the silicone insulation does not bond permanently to the conductor, which would make stripping and termination difficult for technicians.

2. Primary Insulation: Silicone Rubber (HCR)

Each individual core is extruded with High-Consistency Silicone Rubber (HCR). Silicone is a unique inorganic polymer characterized by a backbone of silicon and oxygen atoms. This molecular structure is inherently more stable than the carbon-based backbones of standard plastics.

·         Thermal Range: It remains flexible at temperatures as low as -60°C and maintains its electrical properties at continuous operating temperatures of +180°C to +200°C.

·         Dielectric Strength: Even at high temperatures, silicone provides excellent insulation, preventing current leakage between cores.

3. The Reinforcement: Fiberglass Braiding

Silicone’s primary weakness is its "low tear strength"; it is soft and easily nicked. To solve this, a layer of alkali-free fiberglass yarn is braided over the silicone. This glass braid acts as a mechanical armor. It prevents the silicone from expanding or "bleeding" under high heat and provides critical resistance to cutting and abrasion during installation or when the cable is pulled through metal conduits.

4. Multicore Assembly and Outer Sheath

In a multicore configuration, several of these insulated and braided cores are twisted together. The interstices (the gaps between the circular cores) may be filled with high-temperature fillers to maintain a round cable profile. Finally, an overall outer jacket—either another layer of silicone or a heavy-duty fiberglass braid coated with a high-temperature silicone varnish—is applied. The varnish is essential; it binds the glass fibers together to prevent "fraying" and provides a level of moisture and oil repellency.

Key Performance Characteristics

The adoption of silicone fiberglass multicore cables is driven by several distinct performance advantages that other cable types cannot match:

·         Halogen-Free and Low Toxicity: Unlike PVC, which releases toxic hydrochloric acid gas when burned, silicone is halogen-free. In the event of a fire, it produces minimal smoke.

·         Circuit Integrity (The Silica Effect): One of the most remarkable properties of silicone is its reaction to extreme fire. When consumed by flame, the silicone rubber does not simply melt away; it transforms into a non-conductive silica (SiO2) ash. If the cable is supported by its fiberglass braid, this ash can continue to act as an insulator, allowing critical systems to function long enough for an emergency shutdown.

·         Environmental Stability: These cables are exceptionally resistant to UV radiation and ozone, meaning they do not become brittle or "crack" when exposed to sunlight or high-voltage corona effects over long periods.

·         Chemical Inertness: They show high resistance to many common industrial chemicals, including diluted acids, salts, and certain oils, though they should be shielded from concentrated fuels or solvents.

Industrial Applications and Use Cases

The versatility of the multicore format—allowing for the transmission of both power and control signals in a single cable—makes it indispensable in several high-stakes industries:

Industrial Heating and Furnaces

In the manufacture of glass, steel, and ceramics, ambient temperatures near the machinery often exceed 150°C. Standard wiring would melt, leading to short circuits and dangerous downtime. Silicone fiberglass cables are used to connect heating elements, thermocouples, and sensors within kiln and oven environments.

Plastic Extrusion and Injection Molding

The "hot zones" of plastic processing machinery require constant power and feedback. The constant vibration and high temperatures of the extrusion barrels require a cable that is both thermally stable and mechanically tough enough to withstand the friction of the machine's movements.

Medical and Laboratory Equipment

In sterilized environments or specialized lab settings (such as autoclaves), cables must withstand repeated thermal cycling. The biocompatibility of silicone, combined with the heat resistance of the glass braid, makes these cables ideal for high-end medical monitoring equipment and diagnostic tools.

Aerospace and Railway Technology

Weight and safety are paramount in transport. These cables offer a high power-to-weight ratio and meet stringent fire safety standards (smoke and toxicity) required for wiring in locomotive engine rooms and aircraft galleys.

Technical Specification Summary

Specification

Typical Value

Operating Voltage

300V / 500V or 600V / 1100V

Test Voltage

2000V to 2500V

Temperature Range

-60°C to +180°C (Special grades to 250°C)

Bending Radius

10x to 15x Cable Diameter

Flame Retardant

Per IEC 60332-1 or equivalent

Colors

Multiple core colors for easy identification

Conclusion

The Silicone Fiberglass Insulated Multicore Cable is more than just a wire; it is a highly engineered component designed to thrive where others fail. By leveraging the heat-rejection properties of silicone and the structural rigidity of fiberglass, it provides a safe, durable, and flexible solution for the world's most demanding thermal environments. Whether it is powering a blast furnace or providing control signals to a medical laser, this cable ensures that high temperatures do not result in low performance.

Core Construction and Materials

The performance of these cables is derived from a layered material approach:

1.      Conductor: Typically utilizes flexible stranded tinned copper or nickel-plated copper. Tinning is essential in silicone cables to prevent the rubber from adhering to the copper and to provide corrosion resistance at elevated temperatures.

2.      Primary Insulation: Each core is extruded with High-Consistency Silicone Rubber (HCR). This material maintains its flexibility and electrical properties across a wide thermal spectrum, typically from -60°C to +180°C (short-term up to 200°C+).

3.      Fiberglass Braid: A tightly woven layer of alkali-free fiberglass yarn is applied over the individual core insulation or the overall outer jacket.

4.      Outer Sheath: The multicore assembly is bound by a final silicone jacket or an overall fiberglass braid, often coated with a high-temperature lacquer (such as silicone varnish) to prevent fraying and improve moisture resistance.

Key Technical Advantages

·         Thermal Stability: These cables are designed to operate continuously at high temperatures without becoming brittle. In the event of a fire, the silicone rubber decomposes into a non-conductive silica ash, which can provide a degree of circuit integrity for a short period.

·         Mechanical Protection: While silicone is an excellent insulator, it is naturally soft and prone to tearing. The fiberglass braiding acts as a mechanical "armor," providing significant resistance to abrasion, cutting, and friction.

·         Chemical and Environmental Resistance: The outer construction is resistant to UV radiation, ozone, and various oils and chemicals, making it suitable for harsh industrial environments.

·         Flexibility: Even with the fiberglass reinforcement, the cable remains highly flexible, allowing for easy installation in tight conduits or on complex machinery.

Common Industrial Applications

Given their robust nature, multicore silicone fiberglass cables are frequently found in:

·         Heating Elements: Connecting industrial ovens, furnaces, and kilns where the wiring is exposed to ambient heat.

·         Foundries and Glass Works: Powering equipment near molten metal or glass processing lines.

·         Plastic Processing: Wiring for extrusion lines and injection molding machines.

·         Lighting Systems: High-wattage floodlights and theatrical lighting setups that generate significant heat.

At Themis Automation, we offer high-quality ÖLFLEX® INFRA FR 1X1.5 BK single-core cables from LAPP KABEL, designed for safe and efficient fixed installations.

ISI-marked flame-retardant cable 1.1 kV nominal voltage rating Reduced flame propagation for enhanced safety High conductivity with annealed copper wire Durable FR PVC insulation

Ideal for industrial and electrical installations where safety, durability, and performance matter most.

Upgrade your control and communication systems with UNITRONIC® LIYCY 4x1,5 from LAPP KABEL, offered by Themis Automation. Designed for precision and performance, this low-frequency shielded data cable ensures stable signal transmission in industrial environments.

Key Specifications: 4x1.5 mm² conductor DIN 47100 colour code PVC outer sheath Shielded & flexible design

Features & Benefits: Suitable for computer systems, electronic control & regulation devices Can be used in dry and damp spaces Designed for light mechanical stress PVC sheath offers oil resistance Excellent protection against electromagnetic interference (EMI) Ideal for automation panels, control cabinets, and industrial wiring applications where signal reliability matters.