High-Performance Special Cat 5e Cable for Harsh Environments
High-performance special Cat 5e cable is designed for LVDS signal transmission and special data communication in harsh environments where temperature resistance, shielding performance, low attenuation, capacitance balance, and impedance stability are critical. The THF5eR series supports 100Ω and 120Ω impedance options, 600V AC rating, up to 250MHz operating frequency, shielded constructions, and multiple jacket materials including FEP, silicone rubber, polyurethane, and ethylene-propylene elastomer.
Overview
High-Performance Special Cat 5e Cable is designed for LVDS signal transmission and special data communication in harsh environments where stable impedance, low attenuation, shielding effectiveness, and long-term reliability are required.
The THF5eR series is developed with reference to twisted-pair / star-quad symmetric cable requirements for digital communication and fluoropolymer-insulated aerospace wire and cable principles. By using special materials and shielded structures, this cable supports high and low temperature resistance, corrosion resistance, high flame resistance, aging resistance, impact resistance, low attenuation, good capacitance balance, and stable impedance performance.
This page is intended for product selection. Exact outside diameter, pair count, conductor size, impedance type, jacket material, shielding structure, and test documentation should be confirmed according to project requirements before ordering.
Series Options
The table below helps buyers understand the main THF5eR construction options before reviewing drawings, datasheets, or test requirements.
| Series Option | Product Positioning | Typical Selection Scenario |
|---|---|---|
| THF5eR / 100Ω Type | High-performance special Cat 5e cable with 100±10Ω characteristic impedance | For harsh-environment LVDS or special data communication systems requiring 100Ω impedance, shielded structure, and stable transmission performance. |
| THF5eR / 120Ω Type | High-performance special Cat 5e cable with 120±10Ω characteristic impedance | For applications requiring 120Ω impedance, lower operating capacitance, and stable signal transmission in demanding environments. |
| THF5eR / F Jacket | FEP fluoropolymer jacket version | For applications requiring the widest listed temperature range, from -65°C to +200°C. |
| THF5eR / G Jacket | Silicone rubber jacket version | For applications requiring flexible jacket performance and -50°C to +180°C operating conditions. |
| THF5eR / J Jacket | Polyurethane jacket version | For applications requiring polyurethane jacket performance and -55°C to +105°C operating conditions. |
| THF5eR / E Jacket | Ethylene-propylene elastomer jacket version | For applications requiring elastomeric jacket performance and -45°C to +100°C operating conditions. |
| BYC Custom | Custom special Cat 5e cable construction | For projects requiring custom impedance, conductor size, pair count, shielding, jacket material, outside diameter, marking, testing, or documentation support. |
Features
Special Cat 5e Signal Cable
Designed for LVDS signal transmission and special data communication where stable electrical performance is required in harsh environments.
100Ω and 120Ω Options
Available with 100±10Ω or 120±10Ω characteristic impedance to match different signal transmission requirements.
Up to 250MHz Frequency
Supports a maximum applicable frequency of 250MHz for special data communication and high-performance signal transmission applications.
Multiple Jacket Materials
FEP, silicone rubber, polyurethane, and ethylene-propylene elastomer jacket options support different temperature and application requirements.
Shielded Harsh-Environment Design
Shielded structure helps improve signal stability, reduce interference, and support reliable transmission in demanding electrical environments.
Custom Project Support
BYC Cables can review impedance, pair count, conductor size, jacket material, outside diameter, and testing requirements based on project specifications.
Construction & Materials
The THF5eR series uses special conductor, insulation, shielding, drain wire, jacket, and filler structures to support stable signal transmission and reliable performance in harsh operating conditions. Final construction should be confirmed by impedance type, pair count, conductor size, jacket material, and installation environment.
Construction Options
| Component | Available Options | Selection Notes |
|---|---|---|
| Conductor | 26A, 24A, or 22A conductor options depending on selected structure | Conductor size affects DC resistance, attenuation, outside diameter, and transmission performance. |
| Insulation | Special insulation structure for high-performance data communication cable | Supports capacitance balance, impedance stability, and signal transmission reliability. |
| Pair / Core Structure | 1×2, 2×2, or 4×2 pair structures | Pair count should be selected according to system wiring, LVDS signal layout, and equipment design. |
| Shielding | Pair shielding, overall shielding, or combined shielding structures depending on selected construction | Shielding helps improve EMI protection, reduce crosstalk, and maintain signal integrity. |
| Drain Wire | Bare drain wire or insulated drain wire depending on structure | Drain wire supports shielding termination and grounding requirements. |
| Jacket Material | FEP, silicone rubber, polyurethane, or ethylene-propylene elastomer | Jacket material should be selected according to temperature range, flexibility, abrasion resistance, and environment. |
| Filler | Filler core construction | Supports cable roundness, mechanical stability, and consistent transmission characteristics. |
| Outside Diameter | Varies by impedance type, conductor size, pair count, shielding, and jacket material | Final outside diameter should be confirmed by drawing or selected construction code. |
Jacket and Temperature Options
| Jacket Series | Jacket Material | Operating Temperature |
|---|---|---|
| THF5eR / F | FEP fluoropolymer | -65°C to +200°C |
| THF5eR / G | Silicone rubber | -50°C to +180°C |
| THF5eR / J | Polyurethane | -55°C to +105°C |
| THF5eR / E | Ethylene-propylene elastomer | -45°C to +100°C |
Specifications
The specifications below are intended for preliminary product selection. Final values should be confirmed according to selected impedance type, pair count, conductor size, jacket material, shielding structure, and project standard.
| Product Family | High-Performance Special Cat 5e Cable for Harsh Environments |
|---|---|
| Reference Series | THF5eR series |
| Application | LVDS signal transmission and special data communication in harsh environments |
| Rated Voltage | 600V AC |
| Maximum Applicable Frequency | 250MHz |
| Characteristic Impedance | 100±10Ω or 120±10Ω depending on selected type |
| Pair Structure | 1×2, 2×2, or 4×2 structures |
| Conductor Options | 26A, 24A, or 22A options depending on selected construction |
| Minimum Installation Bending Radius | Not less than 8 times the cable outside diameter |
| Jacket Material Options | FEP fluoropolymer, silicone rubber, polyurethane, or ethylene-propylene elastomer |
| Operating Temperature | Depends on selected jacket material: FEP -65°C to +200°C; silicone rubber -50°C to +180°C; polyurethane -55°C to +105°C; ethylene-propylene elastomer -45°C to +100°C. |
| Outside Diameter | Varies by conductor size, pair count, impedance type, shielding structure, and jacket material. Final OD should be confirmed by drawing or project requirement. |
| Reference Standards | Developed with reference to YD/T838 and GJB773A. These should be treated as reference standards, not third-party certifications. |
| Customization | Available based on drawings, samples, impedance requirements, testing requirements, or project documentation needs |
For accurate quotation, please provide the target impedance, pair count, conductor size, jacket material, shielding requirement, outside diameter requirement, operating temperature, and applicable drawings or test requirements.
100Ω Type Representative Electrical Performance
| Performance Item | Representative Value | Notes |
|---|---|---|
| Conductor DC Resistance at 20°C | 26A ≤12.6 Ω/100m; 24A ≤8.35 Ω/100m; 22A ≤4.95 Ω/100m | Depends on conductor size. |
| Pair DC Resistance Unbalance | ≤0.5% | Applies to listed paired constructions. |
| Voltage Withstand | 2.5kV / 1min, no breakdown | Representative insulation withstand value. |
| Insulation Resistance | ≥5000 MΩ·km | Representative value from product performance table. |
| Working Capacitance | ≤5.8 nF/100m | 100Ω type representative value. |
| Pair-to-Ground Capacitance Unbalance | ≤330 pF/100m | 100Ω type representative value. |
| Characteristic Impedance | 100±10Ω | For 100Ω THF5eR type. |
| Attenuation at 100MHz, 20°C | 26A ≤26.0 dB/100m; 24A ≤24.0 dB/100m; 22A ≤19.5 dB/100m | Depends on conductor size. |
| Structural Return Loss at 100MHz | ≥21.0 dB | Representative value for 100Ω type. |
120Ω Type Representative Electrical Performance
| Performance Item | Representative Value | Notes |
|---|---|---|
| Conductor DC Resistance at 20°C | 26A ≤12.6 Ω/100m; 24A ≤8.35 Ω/100m; 22A ≤4.95 Ω/100m | Depends on conductor size. |
| Pair DC Resistance Unbalance | ≤0.5% | Applies to listed paired constructions. |
| Voltage Withstand | 2.5kV / 1min, no breakdown | Representative insulation withstand value. |
| Insulation Resistance | ≥5000 MΩ·km | Representative value from product performance table. |
| Working Capacitance | ≤4.6 nF/100m | 120Ω type representative value. |
| Pair-to-Ground Capacitance Unbalance | ≤210 pF/100m | 120Ω type representative value. |
| Characteristic Impedance | 120±10Ω | For 120Ω THF5eR type. |
| Attenuation at 100MHz, 20°C | 26A ≤23.0 dB/100m; 24A ≤21.0 dB/100m; 22A ≤16.5 dB/100m | Depends on conductor size. |
| Structural Return Loss at 100MHz | ≥19.0 dB | Representative value for 120Ω type. |
Applications
THF5eR high-performance special Cat 5e cable is suitable for LVDS signal transmission and special data communication systems that must operate reliably under harsh environmental conditions.
LVDS Signal Transmission
For electronic devices and systems requiring stable LVDS signal transmission in demanding environments.
Aerospace & Defense Electronics
For aerospace, defense, and mission-critical equipment requiring shielded, high-reliability data communication cable.
Harsh-Environment Data Systems
For applications exposed to temperature extremes, vibration, corrosion, aging, flame risk, or mechanical impact.
Industrial and Instrumentation Systems
For instruments, sensors, control systems, and electronic equipment requiring stable signal transmission and shielding performance.
Selection Guide
Use this guide as a starting point. Final selection should be confirmed by impedance, conductor size, pair count, jacket material, shielding structure, temperature requirement, and installation environment.
| Requirement | Recommended Type | Selection Reason |
|---|---|---|
| 100Ω signal transmission | 100Ω Type | Suitable when the system requires 100±10Ω characteristic impedance and Cat 5e-style signal performance. |
| 120Ω signal transmission | 120Ω Type | Suitable when the system requires 120±10Ω impedance and lower working capacitance characteristics. |
| Highest listed temperature range | FEP Jacket | THF5eR/F supports -65°C to +200°C and is suitable for the widest listed temperature range. |
| Flexible high-temperature jacket | Silicone Rubber | THF5eR/G supports -50°C to +180°C and can be selected when silicone rubber jacket performance is preferred. |
| Abrasion or mechanical protection needs | Polyurethane | THF5eR/J uses polyurethane jacket and supports -55°C to +105°C operating conditions. |
| Elastomeric jacket requirement | EPR Jacket | THF5eR/E uses ethylene-propylene elastomer jacket and supports -45°C to +100°C operating conditions. |
| Custom structure or test requirement | BYC Custom | BYC Cables can review impedance, pair count, conductor size, jacket material, shielding, outside diameter, and testing requirements. |
Customization Options
BYC Cables can support custom THF5eR special Cat 5e cable requirements based on drawings, samples, electrical specifications, and project documentation needs.
Impedance
100Ω or 120Ω characteristic impedance options can be selected according to system signal transmission requirements.
Pair Count
1×2, 2×2, or 4×2 pair structures can be reviewed based on wiring layout and equipment design.
Conductor Size
26A, 24A, or 22A conductor options can be reviewed according to resistance, attenuation, and size requirements.
Jacket Material
FEP, silicone rubber, polyurethane, or ethylene-propylene elastomer jacket can be selected according to temperature and environmental needs.
Shielding & Grounding
Pair shielding, overall shielding, drain wire, and grounding structures can be reviewed according to EMI and signal integrity requirements.
Testing & Documentation
Electrical performance testing, datasheets, drawings, and technical documentation can be provided based on project requirements.
Request a Quote
Please provide the required impedance, pair count, conductor size, jacket material, shielding requirement, outside diameter requirement, operating temperature, and applicable drawings or test specifications.
FAQ
What is THF5eR special Cat 5e cable used for?
It is used for LVDS signal transmission and special data communication in harsh environments where stable impedance, low attenuation, shielding performance, and cable reliability are required.
Is this a standard commercial Ethernet cable?
No. This is a special high-performance Cat 5e-style cable for harsh-environment LVDS and data communication applications. Final use should be confirmed by system requirements and project specifications.
What impedance options are available?
The THF5eR series includes 100±10Ω and 120±10Ω characteristic impedance options depending on the selected construction.
What jacket materials are available?
Jacket material options include FEP fluoropolymer, silicone rubber, polyurethane, and ethylene-propylene elastomer, each with a different operating temperature range.
What is the maximum applicable frequency?
The maximum applicable frequency is 250MHz. Electrical performance should be confirmed by selected impedance type, conductor size, pair count, and project test requirements.
Can BYC Cables customize this cable?
Yes. BYC Cables can review custom requirements for impedance, pair count, conductor size, shielding, jacket material, outside diameter, marking, testing, and documentation.
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