| Articles : Tinsel Defined |
Tinsel wire is used in applications where
flexibility and durability are the prime concerns of the user.
Tinsel typically consists of a 1/1000 silver coated cadmium copper ribbon that
is wrapped in a helix around a polyester or Kevlar strength member. A larger conductor
consists of 7 bundles of the above; where smaller diameters are required, 3 bundles
are common. Typical break strength with polyester is approximately 18 pounds,
compared to Kevlar with approximately 60 pounds. We stock it extruded in various
thermoplastic materials.
Termination of tinsel normally consists of an insulation displacement style of
crimping. Tinsel containing polyester and/or Kevlar can be soldered under certain
conditions but at a significant break strength reduction.
We are often asked, "What wire gauge (AWG) is Tinsel equivalent
to?"
Since there is more fiber than metal in the bundle, you cannot use the traditional
measure of circular mil area to make the determination. We use a nominal resistance
value of 1000 ft of the conductor to give the customer a working idea. In addition,
Plastics One has begun a testing program to determine the current rating of our most
common tinsel types. This information will be added to our web site (under each
specific tinsel listing) once it becomes available.
The second most frequently asked question is: "How do we terminate
that conductor material?"
Termination of tinsel normally consists of crimping (conventional or insulation
displacement style). We have spent a number of years building and testing termination
equipment based on this technique that will give us good pin retention as well
as good electrical contact. The materials used in the bundles can be soldered
under certain conditions, but at a significant break strength reduction if other
mechanical assists are not put in place. If you have to solder, we recommend
crimping to the conductor with a solderable metal piece before starting. Tinsel
is also compatible with ultrasonic termination techniques.
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