RayFlite High-Voltage Power Cables for High-Altitude Aircraft
RayFlite - Engineered For Next-generation Aerospace Applications
TE Connectivity (TE)’s RayFlite power cables represent a breakthrough in high voltage power distribution technology. Flexible, highly conductive and insulated for application at altitude, RayFlite power cables are specifically designed for the evolving needs of battery powered and hybrid electric aircraft applications.
Powering the Future of Aerospace
TE Connectivity (TE)’s RayFlite power cables represent a breakthrough in high voltage power distribution technology. Flexible, highly conductive and insulated for application at altitude, RayFlite power cables are specifically designed for the evolving needs of battery powered and hybrid electric aircraft applications.
Complete Solution for Next-Generation Aircraft
RayFlite Power Cables are specifically engineered for:
- Hybrid electric propulsion systems
- Battery and hydrogen fuel cell technologies
- UAV power distribution
- High-voltage aerospace applications
Target Markets:
- Commercial aerospace
- Unmanned aerial vehicles
Applications:
- Military and commercial air hybrid electric power, e.g. hydrogen fuel cell, hybrid battery technology
Key Feature and Benefits
Specifically designed for high-voltage, high-altitude applications by engineers that understand the dynamics of power, safety and propulsion
Superior Flexibility:
- Highly flexible conductor and insulation material
- 3x OD bend radius
- Easier installation in tight spaces, reducing assembly time
Altitude-Tested Performance:
- Fully tested at high altitudes for partial discharge
- 1.5 kV AC PDIV at 40,000 ft
- 2 kV AC PDIV at 30,000 ft
- 4 kV AC PDIV at sea level
Enhanced Design:
- Modified ETFE insulation
- Extruded jacket
- High strand nickel coated copper conductor
- Operating temperature rating: 170°C
- Voltage breakdown > 30 kV
System Compatibility:
- Complete connectorized system with TE’s 987 connectors
- Fully tested for partial discharge inception voltage (PDIV) incomplete assembly
- Quantified performance values for total system reliability
Why Choose RayFlite Power Cables?
TE’s RayFlite power cables have been fully tested and validated in our specialized high voltage lab in Swindon, UK. Our cables are bespoke designs specifically engineered for aerospace applications.
The RayFlite Range - RFHVE Series
This is just the beginning. RayFlite RFHVE series power cables are the first of a range of partial discharge free cables. Talk to TE Connectivity about our other high voltage cable designs with optimised weight, flexibility and increased temperature rating, manufactured with TE proprietary materials.
Data for cable at 162 mbar and 170°C, 5X mandrel
*Partial Discharge Inception Voltage is dependent on several factors including altitude, ambient temperature and how the cable is installed. The data chart shows typical partial discharge data (PDIV and PDEV) for cable tested at 43,000 feet and 170C, whilst wrapped around a 5X diameter mandrel.
| Cable | PDIV | PDEV* |
| RFHVE-0418-00-9 | 1650 kV | 1300 kV |
Construction Details
The ‘*’ in the part number shall be replaced by a standard color code designator in accordance with Mil Std 681. ‘e.g. RFHVE-0418-8-9, White Insulation. Standard Color: White Insulation. Other colors available upon request.
| Part Description | Wire Size (AW G) |
Conduc tor Strandi ng No x AWG |
Max. Diam eter (mm) |
Maximum DC Resistance @ 20°C(Ohm s/km) |
Min. Wall Thickn ess (mm) |
Lower Spec Limit |
No m |
Uppe r Spec Limit |
Max. Weigh t (kg/k m) |
| RFHVE-0418-8-* | 8 | 1078 x 38 | 4.57 | 2.33 | 3.10 | 11.55 | 11.90 | 12.26 | 256 |
| RFHVE-0418-6-* | 6 | 1764 x 38 | 5.61 | 1.57 | 3.10 | 12.59 | 12.97 | 13.36 | 331 |
| RFHVE-0418-4-* | 4 | 1666 x 36 | 7.37 | 1.05 | 3.10 | 14.35 | 14.78 | 15.22 | 445 |
| RFHVE-0418-2-* | 2 | 2646 x36 | 8.81 | 0.62 | 3.10 | 15.79 | 16.26 | 16.75 | 603 |
| RFHVE-0418-0-* | 0 | 4256 x 36 | 10.92 | 0.43 | 3.10 | 17.90 | 18.44 | 18.99 | 836 |
| RFHVE-0418-00-* | 00 | 5320 x 36 | 12.10 | 0.33 | 3.10 | 19.08 | 19.65 | 20.24 | 995 |
Partner with TE Connectivity
With decades of experience in critical aerospace applications, TE Connectivity delivers innovative solutions that meet the evolving needs of the aerospace industry.
Contact us today to learn how RayFlite power cables can support your next-generation aircraft design.For more information or to request samples, contact your TE Connectivity representative today.
