Design Considerations for Multi-Conductor Cables
Cable design is as much an art as it is a science. Many factors must be considered during the design phase to insure proper performance. Below is a basic information and checklist for beginning the design process.
Conductors
Specify number and types of conductors
Gauge size of conductors
Insulation type
Color Code
Fillers
Fillers are used to fill space in the cable bundle to maintain cable roundness and uniform flexibility. They also act as cushioning in cables subject to flexing and impact.
Are fillers acceptable?
Fibrillated polypropylene is a commonly used filler. It is non hygroscopic (will not absorb moisture) and forms well in gaps between conductors. Cotton fillers are also common.
Cabling
Several cabling options are available depending on the cables intended use. The cabling process is critical to the performance and dependability of the cable. We recommend that you contact us to draw on our many years of cable design experience to determine which cabling process is best suited for your particular cable construction.
Shielding
Several types of shields are available from Kemcor. Wrapped shields of aluminum/polyester tape, tinned copper, braid, and spiral wrapped shields are all possibilities.
Cable Jacket
Selection of an outer jacket material is based on several factors. The most common factors are cost, durability, and agency approval. Agency such as UL and CSA require selected compounds and wall thickness in order for the product to be labeled with their approval mark. A chart of jacket properties is shown below:
Type Flexibility Abrasion Weathering Temp °F
Vinyls (PVC) better better good -40+220
Polyethylene good good best -65 +160
Polyurethane better best better -65+160
TPE best good good -65+130
Jacket Color
Cable jackets can be matched to any color. Most common and cost effective are the common 10 colors.
Jacket Markings
Agency approved cables, such as UL or CSA, require that certain information be printed on the jacket. In addition to required agency printing, almost any legend can also be printed on the jacket. Most common are customer name, part number or date code.
Above is a basic checklist for cable design. We invite you to contact us for a full review of your cable needs.
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