The only applications where solid wires are typically considered are very high-speed applications. However, these slight benefits are rarely enough to justify their use. Solid wires are slightly cheaper and have a slightly lower resistance compared to the same diameter stranded wire.
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The most popular stranded wires include seven strands, but for applications that need additional flexibility, nineteen strand versions are available. Stranded wires provide improved flexibility, improved flex life, and have significantly better crimpability. However, nickel has an excellent temperature rating (around 250° C). Nickel (260☌ temp rating): Typically only used for high temperature applications, nickel is higher cost and is not as good for terminations and solderability.Silver (200☌ temp rating): Silver has excellent solderability as well as excellent conductivity for high-frequency applications.The downsides to tin is that it introduces soldering challenges due to tin whiskers, and it is a poor high-frequency material. This allows for a crimp to make a solid connection to the copper. Tin (150☌ temp rating): Typically used in low-cost commercial applications, tin provides a protective layer over the copper, ensuring that the copper will not oxidize.To provide better high-frequency performance.To facilitate a simpler and more effective termination (either solder or crimp).Plating is typically added to the wire for three reasons: They have a reduced conductivity but provide improved tensile strength which helps avoid breaking wires, which becomes a challenge with smaller wires. High-strength copper alloys are typically used for space applications and for smaller wires (typically 32 AWG and smaller). There are a few other options such as platinum and stainless steel that are used sparingly, particularly in the medical industry which doesn’t use copper for implantable devices. Copper or copper alloy is the default conductor for nearly all cables used. It provides an excellent balance of conductivity, formability and cost. There are also different platings to be considered, and the question of solid versus stranded wire.īase material - copper versus copper alloyĪs mentioned, copper is the best and most popular option for the base material in wires. There is standard copper and copper alloys. Cables designed correctly should address all the needs of each specific application.Ĭopper is the conductor for nearly all wires that are used in cable-connector assemblies today, but there are several different versions that can be considered. In this discussion, these critical decisions are described. Additionally, various shielding methods must be considered. The conductor, insulation, and jacket material must be chosen careful. Proper cable assembly design takes into consideration many different variables that may impact its mechanical and electrical performance. It protects the wires from the external environment, as well as provides electrical paths for signals to reach their destination. The cable is a critical part of most connector assemblies. A look at Hitachi’s Cat 7 cable shows the different styles of shielding, including wire braid and foil.
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Proper cable assembly design must take into consideration the conductor, insulation, shielding, and jacketing used.Ĭontributed by Ryan Satrom, Signal Integrity Engineer, Omnetics Connector Corp.