Overview

Today's sophisticated electronic systems must maintain stable communications on mobile digital networks because failure is not an option with warfighters' lives and the mission at stake. So, hook-up wires need to be strong enough to withstand harsh conditions without ever breaking or failing.

GORE Hook-Up Wires deliver continuous power while transmitting high-quality signals, so troops can reliably communicate with each other during critical operations. We engineer our wires in a smaller design without jeopardizing mechanical strength or electrical performance. With specialized insulation materials, they can easily tolerate extreme environments, like low/high temperatures, harsh chemicals, complex routing, and severe vibration. These wires are also proven to reduce the risk of abrasion and cut-through.

Cable size comparison

Gore's smaller wire design

Smaller wires with thinner insulation

As more high-tech electronic components are being installed in ground combat/support vehicles, there’s not as much room to route wire bundles.

Our hook-up wires are significantly smaller and require less space — more than 30% than a standard NEMA HP3 Type E wire — because of the thinner insulation that we use in the construction. So, wire by wire, they have a direct impact on saving weight. They’re also more flexible with a tighter bend radius making them perfectly aligned with today’s tight routing.

Whether your function is power or signal, GORE Hook-Up Wires provide the highest level of protection and performance in less space without short-circuiting. Ultimately, they reduce re-work, re-testing, and downtime due to wire failure — which means longer product life and less money you’ll have to spend overall.

Benefits

GORE Hook-Up Wires provide system architects and engineers with many benefits that improve electrical and mechanical performance such as:

  • consistent power delivery with voltage ratings ranging from 100V to 1000V
  • reliable signal integrity in severe conditions without short-circuiting
  • superior cut-through resistance for added strength compared to standard NEMA wires
  • enhanced durability due to temperature-/chemical-resistant insulation materials
  • longer product life with abrasion-resistant and low-creep wire insulation
  • smaller, lighter weight construction for improved installation and weight savings
  • easier routing in confined areas due to greater flexibility and tighter bend radius

For more information about the benefits of our wires, please contact a Gore representative.

Type PTFE

GORE Hook-Up Wires with PTFE insulation are proven to provide a higher level of strength and protection while maintaining reliable electrical performance among critical mission systems.

Type PTFE Details

Tensile strength comparison graph

Tensile strength comparison

Greater Mechanical Strength

Using ASTM D 3032 sections 16 & 17, we compared our wires to leading NEMA wires. Results proved that the overall tensile strength of our hook-up wires is much higher and didn't break or fail at lower temperatures like the other wires. So, even though our wires are smaller and thinner, they’re still very sturdy and will last over the vehicle's lifetime.

Applications

GORE Hook-Up Wires, Type PTFE are engineered to perform reliably in a variety of military applications, including:

  • digital / analog data links
  • ground combat / support vehicles
  • radar systems
  • radio / communications systems
  • surveillance / reconnaissance

If you have any questions or to discuss your specific application needs, please contact a Gore representative.

Properties

These values demonstrate the electrical, mechanical and environmental performance of GORE Hook-Up Wires, Type PTFE.

Download the catalog/data sheets to view product specifications, like AWG sizes, diameter, weight, and minimum bend radius.

Electrical Property Value
Operating Voltage 600
Wrap-Back Test (AC) (kV) 3
Mechanical / Environmental Property Value
Jacket Material PTFE
Jacket Color White (Laser Markable)
Insulation Wall Thickness (mm [in]) 0.14 (0.006)
Conductor Silver-Plated Copper / Nickle-Plated Copper
Conductor Color-Coding Solid Stranded / Striped
Tensile Strength (N) (Insulated Wire) > 100
Dynamic Cut-Through Resistance (N)
(ASTM D 3032/22)
  at +21°C
  at +200°C
  at +260°C		  
 
> 48
> 17
> 12
Scrape Abrasion Resistance (Cycles)
  (ASTM D 1676 / 850 g [1.87 lbs])
  (MIL-DTL-17 / 335 g [0.74 lbs])		  
> 148
> 3
Temperature Range (°C) -65 to +200
Thermoplastic Flow (°C)
(ANSI/NEMA MW 1000-2012)
  24 AWG (07/32) SPC		 > +300
Qualifications

GORE Hook-Up Wires, Type PTFE have undergone substantial qualification testing to ensure they meet stringent specifications of the most current military standards and our customers' requirements.

  • ANSI/NEMA MW 1000-2012: Test Methods for Magnet Wire
  • ASTM D1676/16-17: Test Methods for Film-Insulated Magnet Wire
  • ASTM D3032/22: Test Methods for Hook-Up Wire Insulation
  • MIL-DTL-17: Cables, Radio Frequency, Flexible and Semi-Rigid
  • MIL-STD-104: Limit for Electrical Insulation Color
  • MIL-W-16878/20-22: Wire and Cable Specifications

For more information about the qualifications of our wires, please contact a Gore representative.

Type Halogen-Free

With a unique patented primary insulation, this version of GORE Hook-Up Wires emits low smoke and no halogen when exposed to extremely hot environments. Our inherently non-flammable wires drastically reduce the amount of toxic/corrosive gases emitted during combustion while maintaining stable communications on mobile digital networks.

Type Halogen-Free Details

GORE Hook-Up Wires, Type Halogen-Free

Our halogen-free hook-up wires are smaller in size yet still very resilient, like our PTFE version, for a higher level of durability. This smaller, tougher primary insulation means considerably more flexibility, making it easy to bend them tightly in tiny openings without damaging or breaking them.

Our hook-up wires with halogen-free insulation are ideally suited for all types of ground combat/support vehicles operating in hotter climates.

Applications

GORE Hook-Up Wires, Type Halogen-Free are engineered to perform reliably in a variety of military applications, including:

  • digital / analog data links
  • ground combat / support vehicles
  • radar systems
  • radio / communications systems
  • surveillance / reconnaissance

If you have any questions or to discuss your specific application needs, please contact a Gore representative.

Properties

These values demonstrate the electrical, mechanical and environmental performance of GORE Hook-Up Wires, Type Halogen-Free.

Download the catalog/data sheets to view product specifications, like AWG sizes, diameter, weight, and minimum bend radius.

Electrical Property Value
Operating Voltagea 600
Voltage Resistance (kV) in Water for 5 Minutesb > 10
Mechanical / Environmental Property Value
Jacket Material Thermoplastic Elastomer
Jacket Color Black (Printed)
Jacket Shrinkage (mm [in] at + 220°C)b 0
Conductor Tin-Plated Copper / Nickle-Plated Copper
Conductor Color-Codingc Black, Blue, Brown, Green, Grey, Orange, Purple, Red, White, Yellow
Scrape Abrasion Resistance (Cycles)
(Weight at 6.0 N)b		 100
Accelerated Aging (°C at 120 hours)b +230
Burn Behaviorb
  at maximum Length (mm [in]}
  at maximum Duration (sec.) 		  
75.0 (3.0)
3
Toxicity Indexb 3.7
Smoke Density (Light Transmittance, % per Min.)b 75
Corrosivity of Combustion Gasesb
  at pH (Conductivity of Solutions, μS/mm)		 5.2 (1.5)
Temperature Range (°C) TPC: -65 to +150
NPC: -65 to +190
High Temperature Index (% depth at +220°C)b 0

aStandard versions with voltage ratings of 100, 150, 250, and 1000 are also available.
bTested 16 AWG (19) per VG 95248 Part 2. Test method details available upon request.
cStriped colors available upon request.

Qualifications

GORE Hook-Up Wires, Type Halogen-Free have undergone substantial qualification testing to ensure they meet stringent specifications of the most current military standards and our customers' requirements.

  • ANSI/NEMA MW 1000-2012: Test Methods for Magnet Wire
  • ASTM D1676/16-17: Test Methods for Film-Insulated Magnet Wire
  • ASTM D3032/22: Test Methods for Hook-Up Wire Insulation
  • MIL-DTL-17: Cables, Radio Frequency, Flexible and Semi-Rigid
  • MIL-STD-104: Limit for Electrical Insulation Color
  • MIL-W-16878/20-22: Wire and Cable Specifications
  • VG 95218 Part 2: Performance Specifications for Cables and Insulated Wires

For more information about the qualifications of our wires, please contact a Gore representative.

Resources

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