Tinsel conductors are designed for applications requiring maximum flexibility and fatigue resistance under repeated bending. Their unique construction minimizes mechanical stress, making them ideal for continuous-motion and ultra-flex environments.
Tinsel Conductor Construction
Tinsel conductors are composite designs formed by helically winding flat metal ribbons around a textile core, then twisting multiple composite strands together.
- Copper or copper alloy ribbons
- Textile cores such as polyester, cotton, Nomex, Kevlar, or fiberglass
- Multiple composite strands twisted into a finished conductor
- Extremely low bending stress during motion
This construction allows the conductor to flex without concentrating stress in the metal.
Mechanical Characteristics
- Exceptional flexibility and limpness
- Superior fatigue resistance
- Minimal work hardening under repeated motion
- Not intended for high-current applications
Typical Applications
Tinsel conductors are commonly used in:
- Medical lead wires and patient monitoring cables
- Communications and headset cords
- Retractile and coil cord assemblies
- Specialty cables requiring extreme flex life
Design Considerations
Tinsel conductors are best suited for low-current, high-motion applications where flexibility and service life are critical. Gavitt works with customers to determine when tinsel construction is appropriate based on mechanical demands and electrical requirements.