IEC-Identified, PFA-Insulated Type K for Chemically Demanding Environments
The Short Story
A European temperature-sensor manufacturer needed special-limits Type K (Chromel/Alumel) thermocouple conductors in fine gauges (30–40 AWG) with IEC color identification and chemically robust PFA insulation, delivered repeatably at scale. A peer recommended Pelican Wire for fine-gauge work. We engineered a semi-custom construction that met spec, passed qualification, and has since repeated in multiple orders.
The Problem
- Signal integrity at low mass. Fine-gauge solid conductors (down to 30 AWG / 0.010 in) reduce thermal shunt but amplify any variability in metallurgy, concentricity, or insulation quality.
- European color and identification conventions. The build required IEC color coding on singles with a parallel, clear PFA jacket, a configuration not commonly supported at these gauges by incumbent sources.
- Documentation and traceability. The program needed verifiable quality records suitable for audits and ongoing production control.
The Approach
1) Alloy & Limits of Error
- Matched Type K chemistry and process controls to Special Limits of Error (IEC) expectations.
- Controlled resistivity and homogeneity to minimize drift across expected thermal cycling.
- Documented lot-level conformance so audit trails follow the wire from melt to shipment.
2) Gauge & Geometry Control
- Produced solid 30 AWG conductors (and adjacent sizes) with tight OD and ovality control to maintain nominal finished dimensions at the cable level (parallel lay under a clear PFA jacket).
- Held concentricity within specified tolerances to protect dielectric margins at fine gauges.
3) Insulation System (Chemical & Thermal)
- Specified PFA singles for chemical resistance and continuous-use temperature appropriate to the environment; validated IEC color code on positive/negative legs for visual confirmation in assembly.
- Identified a 300 °C UL-rated insulation path for future variants while preserving the form factor and expanding temperature headroom.
4) Traceability & Documentation
- Provided lot-level certs and inspection records, including measured electrical properties, dimensions, and visual criteria, aligned to the customer’s qualification plan.
5) American Manufacturing Advantages
- Lead-time compression and rapid engineering cycles from our Naples, Florida facility supported faster first-article feedback and qualification.
- Local audit readiness and responsive change control for ongoing production (e.g., PPAP/SQ requirements as applicable).
Results (Summary)
- Met Special Limits for Type K with stable electrical behavior across the operating range.
- Geometry on target: OD, ovality, and concentricity held within tolerance—supporting consistent insulation thickness and dielectric performance.
- Chemical robustness: PFA insulation met the required resistance to cleaning agents and environmental exposure.
- Repeatability at scale: Multiple production runs reproduced the qualified build with tight lot-to-lot variance.
Where This Construction Fits
- Miniature and fine-tip thermocouples where low mass and fast response are critical.
- Sensor assemblies requiring IEC color identification through clear jackets for visual verification.
- Chemically exposed environments needing PFA durability and elevated continuous-use temperature capability.
Talk to Engineering
If you’re targeting fine-gauge Special-Limits Type K with IEC identification and PFA insulation, our team can recommend gauges, geometry, and insulation options that align with your electrical, thermal, and packaging requirements, then document them for smooth qualification and production.