Many thermocouple premature failures are not damaged at the probe end, but broken at the lead section due to poor toughness and anti-fatigue performance. Hot runner molds undergo frequent opening and closing, repeated bending, stretching and extrusion every day. Only thermocouple leads with high toughness, high-temperature aging resistance and anti-tearing performance can withstand long-term mechanical fatigue and maintain stable signal transmission. Inferior brittle leads crack and break easily, causing intermittent signal failure and frequent replacement.
High-quality thermocouple leads adopt special high-temperature resistant mixed polymer insulation material, with excellent flexibility and tensile toughness. It will not harden, crack or become brittle under long-term high-temperature baking and cold and hot alternating environment, and still maintain good bending performance after millions of mold opening cycles. The internal multi-strand alloy wire structure disperses bending stress, avoids concentrated fatigue fracture, and greatly improves anti-breaking ability.
In contrast, low-cost generic leads use recycled inferior insulation materials, which quickly harden and become brittle after a short period of high-temperature operation. Slight bending will cause surface cracking, moisture penetration and internal wire exposure, resulting in short circuit and signal interruption. The single-strand internal wire bears all bending stress, and is easy to break at fixed bending points, forming hidden intermittent faults that are difficult to troubleshoot.
In actual wiring, lead toughness also determines the adaptability to complex routing paths. High-toughness leads can be bent naturally along narrow wiring grooves without damage, while brittle leads cannot adapt to corner layout and are prone to cracking during installation. Regular maintenance should avoid sharp bending and strong pulling, reserve enough bending margin, and prevent lead insulation from being squeezed by mold plates and sharp edges. Choosing thermocouples with high-toughness anti-aging leads can effectively reduce wire breakage failure and extend overall service life.
