This technical description details a custom-engineered thermocouple wire designed for ultra-high accuracy temperature measurement in demanding steam sterilization environments, such as those found in autoclaves within the medical and pharmaceutical industries. This wire solution is engineered to minimize moisture ingress and ensure reliable performance under extreme conditions.
Thermocouple Construction and Properties:
The wire utilizes a Type T thermocouple, employing copper and constantan conductors. These materials are chosen for their stability and accuracy in the temperature range typically encountered in steam sterilization processes. The conductors are 26 AWG, constructed with a 7/34 stranding configuration (7 strands, each comprised of 34 individual wires). This stranded construction provides enhanced flexibility and resistance to fatigue, crucial for applications involving frequent handling and potential vibration. The conductors each have a diameter of 0.019 inches. The thermocouple is manufactured to “Ultra Premium” tolerances, exceeding the accuracy specifications of “Special Limits of Error” wire. This enhanced accuracy ensures precise temperature measurement, critical for validating sterilization processes.
Insulation and Bonding:
The thermocouple conductors are individually insulated with 0.011-inch thick layers of blue and red Fluorinated Ethylene Propylene (FEP). FEP is a high-performance fluoropolymer known for its excellent electrical insulation properties, chemical inertness, and wide operating temperature range. The color coding of the insulation facilitates easy identification and polarity verification during installation. The insulated conductors are then “H-bonded” together. This unique bonding technique creates a robust, inseparable bond between the insulated conductors, eliminating the need for an outer jacket. This construction is crucial for preventing moisture ingress, a common problem in steam sterilization environments.
Finished Dimensions and Construction:
The nominal finished dimensions of the H-bonded thermocouple wire are 0.041 inches by 0.082 inches, resulting in a flat, ribbon-like profile. This profile is designed for optimal space utilization and flexibility within the confined spaces of sterilization equipment. The elimination of an outer jacket significantly reduces the potential for moisture to wick along the wire and reach sensitive instrumentation.
Application and Performance:
This ultra-high accuracy thermocouple wire is designed for use in steam sterilization applications, specifically in autoclaves used in the medical and pharmaceutical industries. The Type T thermocouple, with its “Ultra Premium” tolerances, provides highly accurate temperature measurements, critical for validating sterilization processes and ensuring product safety. The H-bonded construction eliminates the need for an outer jacket, significantly reducing the risk of moisture ingress and protecting sensitive instrumentation from damage.
Technical Considerations:
- Accuracy and Stability: The “Ultra Premium” tolerances ensure highly accurate and stable temperature measurements, exceeding industry standards.
- Moisture Resistance: The H-bonded construction eliminates the need for an outer jacket, minimizing the risk of moisture ingress.
- Chemical Resistance: The FEP insulation provides excellent resistance to chemicals and fluids commonly used in sterilization processes.
- Flex Life: The stranded conductors enhance the wire’s flex life, making it suitable for applications involving frequent handling and potential vibration.
- Dimensional Tolerances: Precise dimensional tolerances are essential for ensuring proper fit and integration within sterilization equipment.
- Temperature Rating: The FEP insulation determines the maximum operating temperature of the wire.
- Calibration: The “Ultra Premium” calibration should be traceable to national standards.
- Dielectric Strength: The insulation’s ability to withstand high voltages without breakdown.
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