Rectangular Cable Assemblies

Space constraints are a significant concern in high-density electrical systems. Rectangular Cable Assemblies are designed with a compact and efficient footprint, allowing optimal conductor density while minimizing the overall system footprint. The rectangular form factor enables the integration of multiple conductors and connectors within a single assembly, maximizing space utilization and improving cable management in compact enclosures or panel designs. This design minimizes the need for excessive routing space, reducing installation time and improving system organization. 

Conductor Material

Tinned Copper / Bare Copper / Silver Plated Copper

Conductor Stranding

7/0.2mm, 19/0.25mm, 37/0.15mm (varies by application)

Voltage Rating

300V, 600V, 1000V (depending on application)

Current Rating

Up to 20A per conductor (based on wire gauge and application)

Insulation Material

PVC, PTFE, Silicone, Fluoropolymer (depending on environment)

Product Description

Maintaining low-noise performance is essential for systems where signal fidelity is critical. Rectangular Cable Assemblies are engineered with advanced shielding techniques to minimize Electromagnetic Interference (EMI) and Radio Frequency Interference (RFI). The assemblies feature multi-layer shielding using foil, braided wire, or conductive polymers, depending on application requirements. This provides superior protection against external sources of interference and ensures high-quality signal transmission in high-speed data applications, including telecommunications, medical equipment, and aerospace. 

Insulation Resistance

PVC, PTFE, Silicone, Fluoropolymer (depending on environment)

Jacket Material

PVC, TPE, PUR, LLDPE (varies based on environmental conditions)

Jacket Thickness

0.5mm – 1.5mm (depending on jacket material and application)

Temperature Range

-40°C to +200°C (varies with material selection)

Flame Retardancy

UL94-V0, UL94-V1, self-extinguishing (depending on insulation)

Shielding

Braided Copper, Foil Shield, or Combination (optional)

Connector Type

D-Sub, MIL-SPEC, Circular, RJ45 (custom options available)

Power Rating

Up to 10kW (based on conductor size and application)

Environmental Rating

IP67, IP68, NEMA 4X (based on jacket and sealing options)

Certification

UL, RoHS, CE, ISO 9001, MIL-STD (depending on configuration)

Technical Advantages

Rectangular Cable Assemblies are designed to operate under extreme environmental conditions. These cables are constructed using materials with high-temperature tolerance, such as fluoropolymer, silicone, and PTFE (Polytetrafluoroethylene), offering resilience in elevated and sub-zero temperatures. Additionally, the cables are resistant to chemical exposure, abrasion, and UV degradation, ensuring durability in challenging environments like automotive, military, and industrial automation. 

Mechanical performance is critical when cables are subject to vibration, flexing, or heavy-duty handling. Our Rectangular Cable Assemblies are engineered with strain relief and rugged outer jackets, typically made from high-strength thermoplastics or thermoplastic elastomers (TPE). These assemblies are designed to withstand high tensile strength and mechanical stress, preventing cable fatigue and failure in robotics, aerospace, and heavy machinery applications. 

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Industry Applications

Semiconductor Manufacturing

Used in wafer handling, process equipment, and automated testing systems to ensure precise signal and power delivery. 

Energy Storage Systems

Facilitates connections in battery management systems (BMS) and energy storage for efficient power regulation and monitoring. 

Robotics

Critical for signal transmission and power distribution in robotic arms, autonomous systems, and precision control units. 

Railway Systems

Ensures reliable power and data transmission in train control, signaling systems, and onboard electronics. 

HVAC Systems

Used in control systems for efficient communication between sensors, actuators, and central control units in HVAC equipment. 

Marine Electronics

Marine Electronics provides power and signal connections for navigation systems, sonar equipment, and underwater communications in maritime applications. 

Electrical Performance and Power Delivery

For applications requiring efficient power transmission and low-voltage drop, our Rectangular Cable Assemblies feature optimized conductor sizes and materials such as stranded or tinned copper to ensure minimum electrical resistance. The conductors are often insulated with cross-linked polyethylene (XLPE) or PVC, providing superior electrical properties while maintaining mechanical flexibility. Additionally, custom options are available for high-current applications requiring thicker conductors or multi-phase configurations. 

In power-intensive systems, managing heat is crucial to maintaining long-term system performance. Our Rectangular Cable Assemblies are designed to improve thermal dissipation through thermally conductive materials and strategic assembly designs that facilitate better heat flow. These assemblies are tested for high thermal conductivity to prevent excessive heating in high-power environments, such as electric vehicles (EVs), power distribution systems, and industrial equipment. 

Having Doubts? Our FAQ

Check all our Frequently Asked Question

How does Frigate ensure the mechanical durability of Rectangular Cable Assemblies used in automotive applications?

Frigate uses high-strength thermoplastic materials and advanced strain relief techniques in its Rectangular Cable Assemblies to withstand high mechanical stresses and vibrations, ensuring reliable performance in demanding automotive environments, including powertrain and infotainment systems. 

What insulation materials does Frigate use for Rectangular Cable Assemblies in high-temperature industrial settings?

Frigate employs silicone, fluoropolymer, and PTFE as insulation materials in its Rectangular Cable Assemblies to ensure optimal performance under extreme temperature conditions. These materials provide insulation stability and long-term reliability in industrial machinery and power distribution systems. 

How does Frigate optimize the EMI shielding in Rectangular Cable Assemblies for sensitive medical equipment?

Frigate utilizes multi-layer shielding, including braided copper and aluminum foil, in its Rectangular Cable Assemblies to prevent electromagnetic interference. This ensures precise signal transmission for high-accuracy medical devices like imaging systems and diagnostic tools. 

What is Frigate's approach to customizing Rectangular Cable Assemblies for military applications?

Frigate customizes Rectangular Cable Assemblies for military applications by selecting high-performance, durable materials that meet MIL-SPEC standards. It incorporates specialized connectors, shielding, and robust insulation to ensure reliable performance in harsh environments such as extreme temperatures and high radiation zones. 

How does Frigate address the issue of signal integrity in Rectangular Cable Assemblies used in aerospace systems?

Frigate uses precision-engineered insulation materials and controlled impedance techniques in its Rectangular Cable Assemblies to ensure minimal signal loss and crosstalk, which are crucial for maintaining signal integrity in high-frequency aerospace communication, navigation, and control systems. 

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LOCATIONS

Global Sales Office

818, Preakness lane, Coppell, Texas, USA – 75019

Registered Office

23, 6th West Street, Balaji Nagar, Kattur,  Pappakuruchi, Tiruchirappalli-620019, Tamil Nadu, India.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ

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Rectangular Cable Assemblies

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