High-Voltage Wire and Cable

Standard and custom high-voltage silicone wire engineered for dielectric stability, flexibility, and consistent electrical performance. Available in standard and dual extruded configurations from 10 kV to 80 kV DC — compatible with Caton high-voltage cable assembly connector platforms and most silicone encapsulation materials.

10–80 kV DC 8–22 AWG Silicone insulation Semi-conductive layer Custom configurations

Overview

Engineered for high-voltage terminations and interconnects

Caton's high-voltage silicone wire is offered in multiple sizes and configurations to meet specific application requirements. The silicone dielectric maintains excellent flexibility over an extreme temperature range and is resistant to radiation, moisture, and weathering.

A semi-conductive silicone layer provides corona resistance by smoothing the electric field at the conductor surface — reducing field concentration that would otherwise initiate corona at the wire's operating voltage. This makes Caton wire compatible with most silicone encapsulation materials and an excellent choice for high-voltage termination applications.

Compatibility with Caton connector platforms

Caton high-voltage wire is designed to be compatible with Caton's 14, 16, 17, and 19 Series connector platforms. Using Caton wire with Caton connectors allows our engineering team to evaluate the complete interconnect — wire, termination, and connector — as a single system. This is the most reliable approach to high-voltage cable assembly integration.

Wire types

Two standard configurations

Caton offers two standard wire constructions. Both use silicone rubber insulation and a semi-conductive corona control layer — they differ in insulation architecture and resulting voltage capability and dimensions.

Higher voltage capability

Dual Extruded HV Wire

Two-layer extrusion with a semi-conductive silicone inner layer over the conductor and a silicone rubber outer insulation. The dual extrusion provides enhanced corona control and supports higher continuous working voltages — up to 30 kV AC / 80 kV DC. Available in 8–22 AWG.

Standard configuration

Standard HV Wire

Single silicone insulation extrusion with semi-conductive corona control. More compact dimensions than dual extruded construction — suitable for applications up to 10 kV AC / 30 kV DC where space constraints are a priority. Available in 10–20 AWG.

Product photography

Wire construction and size range

Dual extruded HV wire

Standard designs — dual extruded

Six standard designs covering 10 kV AC / 30 kV DC through 30 kV AC / 80 kV DC. All dimensions shown are nominal.

Working Voltage		Part No.	Wire Size		Dim A — Conductor		Dim B — Semicon OD		Dim C — Overall OD
kVAC	kVDC		AWG	Stranding	in	mm	in	mm	in	mm
10	30	005639	22	19/34	.032	0.8	.067	1.7	.180	4.6
15	40	0A2841	18	19/30	.051	1.3	.086	2.2	.236	6.0
15	40	CC40415	10	19/25	.126	3.2	.163	4.1	.415	10.5
18	50	002841	14	19/27	.071	1.8	.100	2.5	.300	7.6
20	60	005640	12	19/25	.092	2.3	.134	3.4	.360	9.1
30	80	005641	8	133/29	.150	3.8	.240	6.1	.650	16.5

Dimensions A, B, C correspond to conductor diameter, semi-conductive layer OD, and overall insulation OD respectively. All values nominal.

Standard HV wire

Standard designs — standard wire

Three standard designs covering 5 kV AC / 10 kV DC through 10 kV AC / 30 kV DC. More compact dimensions than dual extruded construction.

Working Voltage		Part No.	Wire Size		Dim A — Conductor OD		Dim B — Overall OD
kVAC	kVDC		AWG	Stranding	in	mm	in	mm
5	10	005636	20	19/32	.040	1.0	.100	2.5
7.5	20	005637	18	19/30	.051	1.3	.140	3.6
10	30	005638	10	19/25	.058	1.5	.180	4.6

Dimensions A and B correspond to conductor diameter and overall insulation OD respectively. All values nominal.

General specifications

Material system and environmental ratings

Conductor — Tin or silver plated copper. Stranded construction for flexibility. AWG 8 through 22 depending on configuration.

Semi-conductive silicone layer — Applied over conductor in dual extruded designs. Smooths the electric field at the conductor surface, reducing field concentration that would initiate corona. Key to the wire's corona resistance at rated voltage.

Silicone rubber insulation — Primary dielectric. Maintains flexibility from -55°C to +125°C. Resistant to radiation, moisture, and weathering. Compatible with most silicone encapsulation materials — making it suitable for high-voltage potted terminations.

Dielectric material	Silicone rubber
Corona control	Semi-conductive silicone layer
Conductor material	Tin or silver plated copper
Operating temperature	-55°C to +125°C
Voltage range	5 kV AC / 10 kV DC to 30 kV AC / 80 kV DC
AWG range	8 AWG through 22 AWG
Encapsulation compatibility	Compatible with most silicone encapsulation materials

Custom configurations

Beyond standard designs

Standard designs cover the most common voltage classes and wire sizes. For applications with requirements outside the standard range — higher voltage, non-standard AWG, specialty conductor materials, or unusual environmental requirements — Caton engineers can evaluate custom wire configurations.

Custom wire configurations are engineered using the same insulation system principles as standard designs — semi-conductive layer for corona control, silicone rubber primary insulation — adapted to the specific voltage, temperature, and environmental requirements of your application.

Custom wire for custom assemblies

Custom wire specifications are most commonly developed as part of a complete custom cable assembly program. When Caton engineers a custom assembly, the wire specification is developed alongside the connector interface and termination design — evaluated as a complete system rather than specified independently.

Related platforms

High-voltage cable assembly series

Wire Datasheet

Complete specifications, dimensions, and part numbers for all standard wire designs.

Download datasheet

Need a custom configuration?

Our engineering team can evaluate custom wire specifications for voltage classes, AWG, or environmental requirements outside the standard range.