Coil cord performance depends on the interaction of conductor construction, insulation and jacket materials, shielding approach, and controlled manufacturing processes. Proper material selection ensures reliable retractability, flexibility, and fatigue life under repeated extension.

Conductor Options

Coil cords may be constructed using conductor types selected for flexibility and durability.

  • Copper Conductors: Good conductivity and general-purpose flexibility
  • Copper Alloy Conductors: Improved fatigue resistance and tensile strength
  • Tinsel Conductors: Maximum flexibility and flex life for low-current applications

Conductor choice influences retractability, memory, and service life.

Insulation Materials

Insulation materials are selected to balance softness, durability, and dimensional stability.

  • Polypropylene
  • Nylon
  • FEP
  • PVC
  • TPE

Soft insulation systems improve flexibility and reduce internal stress during extension and recoil.

Shielding Options

Shielding is used when noise reduction is required without compromising flexibility.

  • Spiral Serve Shields
  • Conductive PVC Shields
  • Combination Shield Designs

Foil and braided shields are generally not recommended for retractile cable designs due to reduced flex life.

Jacket Materials

Jackets protect the internal construction and influence abrasion resistance and handling.

  • Polyurethane
  • PVC
  • Polyurethane / PVC Blends

Jacket selection is based on abrasion exposure, flexibility requirements, and environment.

Manufacturing Considerations

Coil cord performance is influenced by controlled manufacturing processes, including material pairing, internal cable configuration, and coil forming techniques. Consistent processing ensures predictable retractability and long-term durability.

Engineering Support

Gavitt works with customers to evaluate material combinations and construction methods and to develop coil cord designs tailored to specific mechanical and electrical requirements.