Insulated Thermocouple Wire
Insulated Thermocouple Wire is a pre-insulated matched thermocouple alloy pair used for manufacturing miniature and custom thermocouple sensors. Each positive and negative conductor has its own insulation layer, helping prevent short circuits during winding, assembly, and sensor fabrication. K, N, E, J, T, S, R, and B thermocouple types are available. K, N, E, J, and T types are available with conductor diameters from 0.08 mm to 3.0 mm, while S, R, and B types are available in selected fine diameters according to material and insulation requirements. Insulation options include PVC, silicone, PTFE/FEP, fiberglass, and ceramic fiber.
Insulated Thermocouple Wire Features
- Individual wire insulation: Positive and negative thermocouple wires are separately insulated to reduce the risk of short circuits during assembly.
- Full thermocouple series: K, N, E, J, T, S, R, and B types are available.
- Fine conductor diameters: Available from 0.08 mm to 3.0 mm for miniature sensors and different mechanical requirements.
- Multiple insulation options: PVC, silicone rubber, PTFE/FEP, fiberglass, and ceramic fiber for different temperature ranges.
- Fast thermal response: Fine-diameter wire has low thermal mass for rapid temperature measurement.
- Custom fabrication: Supplied on spools with custom cut-to-length service available.
Working Principle
Insulated thermocouple wire consists of two dissimilar thermocouple alloy conductors. A temperature difference between the measuring junction and reference junction generates a thermoelectric voltage that can be converted into a temperature reading.
Unlike Bare Thermocouple Wire, both positive and negative legs are covered with individual insulation layers. Only the required measuring tip is stripped and joined by spot welding or argon-arc welding to form the thermocouple junction.
Supported Thermocouple Types
For help comparing K, J, T, E, N, S, R, and B thermocouple options, see our thermocouple types selection guide.
| Thermocouple Type | Alloy Combination |
|---|---|
| K-Type | NiCr-NiSi |
| N-Type | NiCrSi-NiSi |
| E-Type | NiCr-CuNi |
| J-Type | Fe-CuNi |
| T-Type | Cu-CuNi |
| S-Type | PtRh10-Pt |
| R-Type | PtRh13-Pt |
| B-Type | PtRh30-PtRh6 |
Construction Options
Conductor Diameter
Available conductor diameters include 0.08 mm, 0.1 mm, 0.2 mm, 0.3 mm, 0.5 mm, 0.8 mm, 1.0 mm, 1.5 mm, 2.0 mm, and 3.0 mm.
Fine-diameter conductors are suitable for miniature sensors and fast response measurement, while larger diameters provide greater mechanical strength and longer service life.
Insulation Material & Temperature Range
The temperature ranges below refer to the typical continuous service temperature of the insulation material. The actual allowable temperature also depends on conductor type, diameter, construction, and application conditions.
| Insulation Material | Continuous Temperature | Application Feature |
|---|---|---|
| PVC | -20 to +105°C | Economical, indoor low-temperature assembly |
| Silicone Rubber | -40 to +180°C | Soft, flexible, good bending performance |
| PTFE / FEP | -60 to +260°C | Anti-corrosion, moisture-resistant, chemical-resistant |
| Fiberglass | -40 to +480°C | Dry high-temperature environment |
| Ceramic Fiber | -40 to +700°C | Ultra-high temperature, custom item |
Accuracy Grade
Insulated thermocouple wire is manufactured according to IEC 60584-1.
- Class 2: Standard supply for general industrial temperature measurement.
- Class 1: Optional for applications requiring tighter measurement accuracy.
Product Structure
Positive thermocouple alloy with individual insulation + negative thermocouple alloy with individual insulation.
The positive and negative wires remain separately insulated along the cable length. Only the measuring tip is stripped and welded to form the thermocouple junction.
Installation & Operation Notice
- Keep the insulation intact except at the required welding measuring tip. Damaged insulation can cause short circuits and measurement errors.
- The maximum working temperature depends on both conductor diameter and insulation material.
- S/R/B platinum-rhodium insulated wire is suitable for oxidizing or inert atmospheres. Avoid long-term reducing gas environments.
- The measuring junction can be formed by spot welding or argon-arc welding. Keep the welding point clean and secure.
- Do not directly immerse insulated thermocouple wire in strong corrosive media without a suitable outer protection sheath.
Application Scenarios
Insulated Thermocouple Wire is commonly used for:
- Miniature thermocouple sensor manufacturing
- Mold and hot runner temperature testing
- Laboratory rapid-response temperature measurement
- 3D printer heating cartridge temperature sensing
- R&D custom temperature probes
- Needle and exposed-junction thermocouple sensor fabrication
- Small-space temperature monitoring
Standard Specification Table
| Thermocouple Type | Alloy Combination | Available Diameter | Insulation Options |
|---|---|---|---|
| K-Type | NiCr-NiSi | 0.08-3.0 mm | PVC / Silicone / PTFE / Fiberglass / Ceramic Fiber |
| N-Type | NiCrSi-NiSi | 0.08-3.0 mm | PVC / Silicone / PTFE / Fiberglass / Ceramic Fiber |
| E-Type | NiCr-CuNi | 0.08-3.0 mm | PVC / Silicone / PTFE / Fiberglass |
| J-Type | Fe-CuNi | 0.08-3.0 mm | PVC / Silicone / PTFE / Fiberglass |
| T-Type | Cu-CuNi | 0.08-3.0 mm | PVC / Silicone / PTFE / Fiberglass |
| S-Type | PtRh10-Pt | 0.1-1.0 mm | PTFE / Fiberglass |
| R-Type | PtRh13-Pt | 0.1-1.0 mm | PTFE / Fiberglass |
| B-Type | PtRh30-PtRh6 | 0.1-1.0 mm | PTFE / Fiberglass |
Positive and negative wires are individually insulated and supplied as a matched pair on a spool. Fine-diameter wire provides faster response but lower mechanical strength. Fiberglass and ceramic fiber insulated wire should be used in dry environments and should not be immersed in liquid. S/R/B platinum-rhodium insulated wire should avoid long-term reducing atmospheres. Sold per meter or full spool; custom cutting is available.
Related Thermocouple Products
High-Temperature Thermocouple Extension & Compensating Cable
Thermocouple Wire & Extension Cable
Request OEM Thermocouple Wire Support
For OEM or custom thermocouple wire requirements, please provide the thermocouple type, conductor diameter, insulation material, required length, accuracy grade, and application conditions. Drawings, photos, or existing samples are welcome.
Amy – Sales
Email:
Amy-Easewise@tzheater.com
WhatsApp:
+86 188 8318 8154
Hanna – Sales
Email:
Hanna-Easewise@tzheater.com
WhatsApp:
+86 173 5163 6811
Custom insulated thermocouple wire is available for miniature sensor manufacturing, laboratory testing, hot runner applications, and OEM thermocouple production.
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