4core: Features four Insulated Conductors, typically used for basic security setups (e.g., 2 door sensors + 1 siren + 1 Power Line).

6core: Suitable for mid-sized systems, supporting 3–4 devices (e.g., 2 motion detectors + 1 smoke sensor + 1 keypad + power/data lines).

8core: Designed for commercial systems with multiple zones, accommodating 5–6 devices (e.g., 3 access control readers + 2 CCTV cameras + 1 fire alarm).

10core: Ideal for large-scale installations (e.g., shopping malls, office complexes), supporting 7–8 devices with dedicated cores for diagnostics and redundancy.

Bare Copper:

Copper-Clad Aluminum (CCA):

Conductor Insulation:

Outer Jacket:

Tensile strength: ≥15 N/mm² (PVC Jacket) to withstand pulling during installation.

Abrasion resistance: Passes 10,000 cycles of rubbing with a weighted abrasive wheel (per IEC 60811-2-1).

Moisture resistance: IP40 rating (splash-resistant), suitable for indoor and protected outdoor use (e.g., under eaves).

4Core Cables: Commonly used in small homes to connect a control panel to 2–3 devices (e.g., 1 door sensor, 1 motion detector, and 1 siren). The 4 Cores are split into power (2 Cores) and signal (2 cores) to ensure redundancy. For example, if one signal core fails, the system switches to the backup core, preventing security gaps.

6core Cables: Suitable for larger homes with expanded security needs, such as 3–4 sensors (e.g., 2 window contacts, 1 garage door sensor, 1 smoke detector). Extra cores allow for future upgrades (e.g., adding a keypad without rewiring).

6core–8core Cables: Used in stores, restaurants, and offices to link multiple zones. For instance, an 8core cable in a retail store might connect:

10core Cables: Deployed in large commercial buildings (e.g., malls, hotels) with integrated systems. They support:

8core–10core Cables: Used in warehouses, factories, and data centers, where security systems interface with industrial equipment. For example:

Humid Areas (e.g., basements, coastal homes): Cables with PE insulation (instead of PVC) are preferred for better moisture resistance, preventing insulation degradation over time.

Cold Climates: TPE-insulated conductors enhance flexibility in sub-zero temperatures, avoiding cracking during installation in frozen walls or attics.

Bare Copper: High-purity (99.9%) electrolytic copper is used for its superior conductivity. The copper is annealed (heated to 600°C and slowly cooled) to soften the metal, improving strand flexibility. This annealing process prevents conductor breakage during repeated bending—critical for routing through tight spaces like wall studs or conduit elbows.

Copper-Clad Aluminum (CCA): Aluminum cores (90% of volume) are coated with 10–15% pure copper via electroplating. The aluminum reduces weight and cost, while the copper coating ensures compatibility with standard connectors (e.g., crimp terminals, screw blocks) that rely on copper’s conductivity for proper contact.

PVC: The most common insulation due to its low cost, flexibility, and resistance to oils and chemicals. PVC Insulation is formulated with plasticizers (e.g., dioctyl phthalate) to maintain flexibility at low temperatures and stabilizers (e.g., calcium-zinc compounds) to prevent UV degradation.

PE (Polyethylene): Used in humid environments for its water resistance. PE has a lower dielectric constant than PVC (2.3 vs. 3.0), reducing signal attenuation in long runs.

TPE (Thermoplastic Elastomer): A blend of plastic and rubber, offering superior flexibility in extreme temperatures (-40°C to 90°C). TPE is used in Industrial Cables where frequent movement (e.g., near sliding doors, conveyor belts) could stress rigid insulation.

Antimony trioxide (flame retardant) to meet UL 94 V-0 standards.

Carbon black (UV stabilizer) for outdoor use, preventing jacket cracking from sunlight exposure.

Fillers (e.g., calcium carbonate) to enhance mechanical strength without increasing cost.

Binder Tape: A thin polyester tape wraps around the bundled cores to maintain shape during jacket extrusion, preventing core shifting that could cause short circuits.

Ripcord: A nylon string embedded under the jacket for easy stripping during termination, reducing installation time.

Bare Copper Stranding: Copper Wires (0.16 mm or 0.20 mm diameter) are fed into a stranding machine, which twists 19 strands into a single conductor. The lay length (distance per twist) is set to 10–15 mm for 22 AWG and 15–20 mm for 20 AWG, balancing flexibility and structural stability.

CCA Production: Aluminum Wires are first drawn to the desired diameter, then electroplated with copper in a bath of copper sulfate. The plating thickness is controlled to 5–10 μm (micro meters) to ensure conductivity while minimizing copper usage. The CCA wires are then stranded using the same process as bare copper.

Individual conductors are fed into an extrusion line, where molten PVC (or PE/TPE) is applied through a die. The insulation thickness is monitored by laser gauges, with feedback loops adjusting the extrusion rate to maintain ±0.02 mm tolerance.

After extrusion, the insulated conductors are cooled in a water bath and spooled. Each spool is color-coded to match the insulation, ensuring correct core identification during later stages.

For Multi-Core Cables, insulated conductors are pulled from spools and bundled together, with a binder tape wrapped around them to secure the arrangement. The number of cores (4–10) is verified by automated counters to prevent errors.

The bundled cores enter a second extrusion machine, where the outer PVC jacket is applied. The jacket thickness is controlled based on core count: 0.5 mm for 4–6 cores, 0.8 mm for 8–10 cores. The extrusion die is shaped to ensure a uniform cylindrical profile, with a ripcord embedded between the binder tape and jacket.

The jacketed cable is cooled, then pulled through a diameter gauge to verify dimensions. It is then cut into standard lengths (100m, 500m, 1000m) and wound onto reels.

Conductor Resistance: Tested with a micro-ohmmeter to ensure compliance (e.g., ≤53.5 Ω/km for 22 AWG copper).

Insulation Integrity: A 1kV AC voltage is applied between cores for 1 minute; no breakdown indicates 合格 (pass).

Flame Retardancy: Samples are subjected to UL 94 V-0 testing, with flame spread and burn time measured.

Flexibility Test: Cables are bent 180° around a mandrel (diameter = 6x cable diameter) 10,000 times; no conductor breakage or insulation cracking is allowed.

Reel Types:

Reel Features:

For large orders, 1000m+ cables are wound into coils and wrapped in moisture-resistant plastic film. Each coil includes a label with the same information as reels, plus a handling guide.

Custom packaging options are available for wholesale clients, such as:

Road Transport: Used for domestic shipments (≤500km). Cables are loaded onto enclosed trucks to protect from rain, snow, and UV exposure. Reels are secured with straps to prevent movement during transit.

Rail/Sea Transport: For international or long-distance domestic shipments, reels are loaded into shipping containers. Palletized reels are stacked with dunnage (wooden blocks) to prevent shifting. Climate-controlled containers are used for sensitive regions (e.g., tropical areas with high humidity).

Air Freight: Rarely used due to cost, but available for urgent orders (e.g., 1–2 reels for emergency security system repairs).

Reels must be lifted with forklifts or cranes using designated lifting holes; dragging reels is prohibited to avoid jacket abrasion.

Cables should be stored upright (flanges vertical) to prevent core deformation.

Temperature during transport must remain within -20°C to 60°C to avoid insulation cracking (cold) or softening (heat).

Upon receiving an order, manufacturers verify specifications (core count, gauge, conductor material) and check inventory. In-stock items are processed within 24–48 hours; custom orders (e.g., specific colors, lengths) take 5–7 business days.

Customers receive an order confirmation with details: product type, quantity, total length, shipping method, estimated delivery date, and tracking number.

Real-time tracking is provided via the manufacturer’s website or third-party logistics (3PL) partners (e.g., DHL, FedEx). Customers receive automated updates via email/SMS at key stages:

Upon receipt, customers should inspect reels for:

Any issues must be reported within 48 hours, with photos/videos as evidence. Manufacturers arrange replacements for damaged goods at no cost.

Standard samples are 1–5m lengths of 4core, 6core, 8core, or 10core cables, available in both copper and CCA variants.

Custom samples (e.g., specific insulation colors, TPE insulation) can be produced upon request, with a 3–5 day lead time.

Customers request samples via the manufacturer’s website, email, or sales team, specifying core count, gauge, conductor material, and quantity.

Samples are typically free for qualified customers (e.g., security system installers, distributors), with shipping costs covered by the customer or manufacturer (for bulk order commitments).

Customers can test samples for:

Engineers provide guidance on:

Standard warranty: 5 years, covering defects in materials/workmanship (e.g., insulation failure, conductor breakage under normal use).

Warranty claims require proof of purchase and photos of the issue.

Unused cables in original packaging can be returned within 30 days for a full refund.

Defective cables are replaced free of charge, with expedited shipping for critical projects.

Customer feedback is collected via surveys to improve: