Composite power cables serve a multitude of purposes in even the most strenuous environments. These cables are strong and durable and can withstand abuse from the elements for long periods of time, ensuring that they remain functional in the toughest of climates. Sometimes a power cable by itself isn't enough for an application, so a custom composite cable is needed.
Our Custom Composite Cable Solution
One customer came to Allied Wire and Cable with a design and confidence, knowing we would help them since we had designed cable solutions for them in the past. This time, the custom power cable we were asked to manufacture was for a piece of oil field equipment. The custom composite power cable would be run from a control panel to a tool that could produce high temperatures and carry a high voltage.
The custom composite cable specifications called for two 10 AWG power wires with four, smaller data wire pairs of different sizes. All of the conductors were tinned copper conductors insulated with FEP. In addition to its wide operating temperature range, FEP insulation is also resistant to solvents, acids, alkalis, ozone, and oils— an important characteristic in many pipeline projects.
These pairs were bound together under a thermoplastic elastomer jacket, which was moldable and retained the flexibility and stretch of rubber. TPE is not typically used for heat or chemical resistance, but since the jacket would be stripped back and away from the heat, this durable material was a suitable option.
The customers' assigned Allied Wire and Cable sales representative had only one suggestion to improve the custom cable design: to use a stranded conductor construction, rather than solid, so that the flexibility of the conductor would match that of the insulation and jacket. The customer agreed, and the specifications were adjusted before finalizing the order. From there, the sales representative was able to expedite the cable manufacturing process to meet the demands of the customer’s tight schedule.
Sometimes an application has limited space but needs multiple cables to perform different functions. That's where hybrid composite cables from Allied Wire and Cable come in. Do you have a custom cable already designed and need suggestions? Allied Wire and Cable can help. Visit our Custom Cable Design Center to get started.