Braids
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Conductor Plating Basics
Cable Shielding: When? Why?
Why are shields used in electrical cable?
In addition to the benefit of protection against damage to cable components from cable motion and use, proper shielding is essential to many applications as it can keep out unwanted external interference. In many applications, electromagnetic interference (EMI) is a threat to signal integrity. Shield quality is of particular importance in small signal or high frequency applications where a slight variation can have significant impact. All electrical cable will radiate energy to, and pick up energy from, its surroundings. As such, shielding can also be used to contain the electromagnetic energy radiated by a cable, which can protect nearby sensitive components.
The types of shields used by New England Wire
The three most common shield types used by New England Wire for multi-conductor cable are braid, spiral, and foil. A braided shield is made of interwoven conductive wire. A braid can be manufactured using a wide variety of materials and wire sizes and can be applied over an extensive range of cable diameters. A spiral shield is made of conductive wire helically wrapped over the core. As with a braid, a variety of materials and wire sizes can be used, however, spiral shields are generally limited to small or mid-sized cables in order to achieve high coverage. A foil shield is a metallic foil helically wrapped around the cable with overlap. A variety of foil options can be utilized, however, most common is aluminum laminated with a polyester backing. Variations or combinations of the standard types are often used to provide a custom solution to a particular application.
In addition to wire and foil based shielding options, we can also manufacture with semi-conductive tapes, coatings or extruded layers. These are typically used in conjunction with wire based shields to provide additional shielding, but more notably, they are used for low noise or corona resistant high voltage cables.
So which shield type is best?
The ideal shielding method for any application depends on the specific application for which it is going to be used. For example, shielding effectiveness at low frequencies is largely influenced by resistance. Therefore, wire based shields such as spirals and braids are ideal. At high frequencies, coverage becomes the primary factor making 100% coverage foil shields the most effective option. At mid-range frequencies both resistance and coverage are influential so a high coverage braid is typically used.
While shielding effectiveness is often one of the primary concerns for most applications, other impacts of shielding should be considered. Design constraints such as flexibility, flex life, diameter, weight, and cost may influence the shield selection. Furthermore, in order to get the full benefit of shielding, the shield must be grounded properly, consequently, means of termination can play a role in shield selection.
Variations or combinations of the standard shield types are often used to maximize shielding effectiveness for a given application. For example, stacking a foil and braid will provide a shield with 100% coverage and low resistance making it effective from low to high frequencies.
| Standard Shield Options | Braid | Spiral | Foil |
|---|---|---|---|
| Description | • Metallic wire interwoven to from a tubular structure • May also be formed to a rectangular cross section | •Metallic wire helically wrapped around a core | •Metallic foil typically laminated to a thermoplastic layer wrapped around a core with overlap |
| Core Size | .012" and larger | .004" - .450" | .025" and Larger |
| Single End AWG Range | 30-46 AWG | 36-52 AWG | N/A |
| Flexibility | Good | Very Good | Poor |
| Flex Life - Continuous Flexing | Good | Poor | Poor |
| Typical Coverage | 90% | 90-95% | 100% |
| Typical Frequency Range | Low to mid frequencies (Up to 100 MHz) | Low frequencies (Up to about 1 MHz) | High frequencies (Greater than 100MHz) |
| Ease of Termination | • Braided wire can be separated and terminated •Can be challenging so a drain wire is sometimes used | •Not interwoven so easy to terminate using individual shield wires or multiple strands twisted together | •Difficult •A drain wire is often beneficial |
| Advantages | •Provides structual integrity while still maintaining good flexibility and flex life with contnuious flexing •Lowest resistance •Provides other mechanical benefits (cut through/crush resistance) | •Most flexible option •Less build than braid •Can be easily manufactured with 95% coverage •Less weight | •Provides 100% coverage allowing effectiveness at high frequencies •If aluminum foil used, this option offers low weight and cost |
| Concerns | •Largest increase in OD •Brain pattern limits maximum coverage to 95%, gaps in braid limit effectiveness at high frequencies | •If bent or flexed in use the spiral can open up limiting effectiveness to lower frequencies •Inductive effect as a result of shield wires helically wrapped around core | •High resistance limits effectiveness at low frequencies •Not recommended for continuous flexing applications •Termination options are limited |
Take a Virtual Tour Of New England Wire!
Conductor Materials
New England Wire Technologies is well known in the industry as a manufacturer of high-quality braided wire products as well as flexible cables and strands which are used primarily in our specialty single and multi-conductor cables. We offer a full range of conductor materials including bare, tin, nickel and silver plated copper, a wide variety of alloys (bare and plated), pure nickel or silver, various stainless steels, Monel®, MuMETAL®, and bronze, as well as textiles (nylon, cotton, fiberglass, Aramid, polyester) and monofilament.
The chart below may help you in choosing the appropriate material for your application.
| NEWT Designation | Description | Conductivity (% IACS) | Tensile Strength (psi) | Yield Strength (psi) | Elongation | Applicable ASTM Standards | Typical Uses/Benefits | |||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Soft | Hard | Soft | Hard | Soft | Hard | |||||||
| NEWaloy 10 | ETP Copper | 100% Min | 35,000 Nom | 60,000 Nom | 10,000 Nom | 50,000 Nom | 10-25% | 1% Nom | ASTM B1/B3 ASTM B258 | The standard for the wire and cable industry, generally annealed (soft) except for 47-50 AWG | ||
| NEWaloy 11 | OF Copper (Grade 1) | 101% Min | 35,000 Nom | 60,000 Nom | 10,000 Nom | 50,000 Nom | 10-25% | 1% Nom | ASTM B1/B3 ASTM B258 | When the highest conductivity is required or in hydrogen rich environments, generally annealed | ||
| NEWaloy 13 | RoHS compliant High Strength Alloy | 73% Nom (hard) | 40,000 Nom | 90,000 Min | 30,000 Nom | 80,000 Nom | 10-25% | 1% Nom | ASTM B250 ASTM B258 | Mechanically demanding applications, high flex or continuous flex, hard-drawn typically used (see Newaloy23) | ||
| NEWaloy 14 | RoHS compliant Alloy | 85% Min | 55,000 Min (only 1 temper) | 35,000 Nom | 6% Min | ASTM B258 | ||||||
| NEWaloy 21 | OF Copper (Grade 2) | 100% Min | 35,000 Nom | 60,000 Nom | 10,000 Nom | 50,000 Nom | 10-25% | 1% Nom | ASTM B1 or B3 ASTM B258 | When the highest conductivity is required or in hydrogen rich environments, generally annealed | ||
| NEWaloy 23 | RoHS compliant High Strength Alloy | 77% Nom (hard) | 90,000 Min | 80,000 Nom | 1% Nom | ASTM B250 ASTM B258 | Mechanically demanding applications, high flex or continuous flex, hard-drawn typically used | |||||
| NEWaloy 61 | Cad-Copper (Not RoHS Compliant) | 80% Nom | 85,000 Min | 80,000 Nom | 1% Nom | ASTM B105 ASTM B258 | Mechanically demanding applications, high flex or continuous flex, hard-drawn typically used | |||||
| NEWaloy 81 | Cad-Chromium Copper (Not RoHS Compliant) | 85% Min | 60,000 Min (only 1 temper) | 40,000 Nom | 6-8% Min (varies with size) | ASTM B624 ASTM B258 | Significant improvement in flex life versus copper with a minimal loss in conductivity | |||||
| NEWaloy 15, 25, 75 | Phosphor Bronze (Resistance Wire) | Varies according to grade, size, & coating | Varies according to Grade | Varies according to Grade | Varies according to Grade | ASTM B105 ASTM B258 | Resistance wire, various grades are available to achieve a specific resistance | |||||
| Aluminum 1350 | EC Grade Aluminum | 61.8% Nom (soft) | 8,500-14,000 | 27,000 Nom | 4,000 Nom | 24,000 Nom | 23% Nom | 1.4% Nom | ASTM B230/B609 ASTM B258 | When keeping weight low is the primary design goal | ||
| Aluminum 5052 | Aluminum Alloy | 33.6-37.6% (soft) | 32,000 Max | 34,000 Min | 9.500 Nom | 26,000 Min | 25% Nom | 1% Nom | ASTM B211 ASTM B258 | When low weight is the primary design goal but with improved mechanical properties | ||
| Stainless Steel | 304 or 316L, others available | 2.3 - 2.4% Nom for Standard Grades | 75,000 Min | various grades & tempers | 30,000 Min | Various grades and tempers | 25% Min | various grades and tempers | ASTM A580 ASTM B258 | Small but high strength signal wire, crush resistant shields or as a strength member | ||
| CCA | Copper Clad Aluminum | Depends on temper & Copper:Aluminum ratio. 62.9% Min for Class 10A (soft, 10% Copper) | 25,000 Max | 30,000 min | 12,000 Nom | 22,000 Nom | 5% Min | 1% Min | ASTM B566 ASTM B258 | Low weight but with increased conductivity and ease of termination provided by copper surface, high frequency applications (skin effect will cause current to run primarily in copper) | ||
| CCS | Copper Clad Steel | Typically 40%. 30% also available with slightly improved mechanical properties | 50,000 Min (Class 40) | 110,000 Min (Class 40) | 10% Min | 1% Min | ASTM B452 ASTM B258 | Very high flex life and tensile strength with reasonable conductivity, high frequency applications (skin effect will cause current to run primarily in copper | ||||
| Tinsel Wire | Flat Wire helically wrapped around textile core | Varies according to type | Varies according to type | Varies according to type | Varies according to type | Offers extremely high flex life along with high flexibility and tensile strength when the increase in diameter can be tolerated | ||||||
| Thermocouple Wire | Extension Wire for Types E, J, K, T, etc. | Varies according to type | Varies according to type | Varies according to type | Varies according to type | ASTM E230 ASTM B258 | To connect a thermocouple probe to the device that reads the signal. Using identical metals as the probe itself allows for accurate reading | |||||
| Silver | Pure Silver | 1.06 | 21,000 Nom | 50,000 Nom | 8,000 Nom | Highest thermal and electrical conductivity at room temperature of all metals | ||||||
| Magnet Wire | Enamel Coated Conductor | Varies according to conductor material. Typically 100% Copper | Varies according to type | Varies according to material | Varies according to material | ASTM D1676 ASTM D2307 | High frequency applications - the enamel insulates each individual strand increasing efficiency. See Litz (link to Litz) | |||||
| Superconductor | Resistance = 0 below critical temperature | N/A | Varies according to type | Varies according to type | Varies according to type | High energy applications needing extreme efficiency: MAGLEV, MRI, particle accelerators |
Wire Plating Options
In addition to the selection of base metal and stranding technique, plating is an option to maximize and customize the properties of a conductor. Plating offers a relatively inexpensive means of combining the advantages of two metals.
The conductors and shields of multi-conductor cable are typically manufactured using copper or copper-based alloy as the base metal primarily due to these materials’ high conductivity, good mechanical performance and reasonable cost. While copper-based materials offer numerous benefits as electrical conductors, many applications require properties beyond what non-coated wire can provide. These properties include solderability, temperature range, contact resistance or corrosion, and chemical resistance; therefore, in order to improve one or more of the above properties, conductors are often plated. A variety of metals can be used for plating; however, tin, silver, and nickel are by far the most common.
Tin is the most common coating for copper and copper alloys due to low cost and very good solderability. Improved corrosion and chemical resistance is also an advantage of tin plating (but is dependent upon coating thickness). Tin has a relatively low melting temperature and therefore provides little, if any, improvement to the operating temperature range of copper. Also, tin has relatively low conductivity and, when plated over copper, forms an inter-metallic layer which will increase resistance compared to bare or silver plated wire.
Silver offers extremely high conductivity and will actually reduce the resistance of plated wire. This is particularly beneficial in high frequency applications because the skin effect will result in increased current flow through the silver. In addition to conductivity, silver plating copper will increase high temperature performance and generally improve chemical resistance. Solderability of silver plated conductors is excellent and while silver may experience some oxidation, silver oxide is a conducting material so the impact on solderability is not significant. While silver plating offers many advantages over tinned or uncoated copper, the added cost is a consideration.
Nickel is a much harder metal than other common plating options and offers excellent resistance to high temperatures. The operating temperature range increase due to nickel plating depends on the thickness of the plating but is superior to that gained by using silver. Nickel is very resistant to harsh environments and corrosion; however, due to its hardness, soldering can be difficult and requires an activated flux. Crimp termination can be a good option for nickel plated wire, but, because it is a hard material, some adjustments to tooling may be necessary. Conductivity of nickel is relatively low and plating will increase the resistance of wire (much like the impact of tin plating).
New England Wire Technologies has in-house plating facilities for tin and silver to meet your specific requirements or to ASTM standards. In addition to those discussed, New England Wire has utilized numerous other plating options including gold, chrome and Stay-brite®. We have extensive experience manufacturing custom wire and cable with plated materials and can work with you to select the appropriate option for your application.
Stay-brite® is a registered trademark of Harris Products Group.
Do You Need Custom Cable?
A common question asked of the sales and engineering staff at New England Wire Technologies by those unfamiliar with our company is why a custom cable solution should be considered when there are so many off the shelf options out there. This is a very reasonable question and in some cases a standard product does make sense. However, when electrical device and component manufacturers stop to consider what properties would be ideal to meet the demanding requirements of their application and what level of service and quality they expect from their suppliers, the advantage of a custom cable solution from New England Wire Technologies becomes apparent.
The most immediate benefit of a custom solution is the knowledge and design assistance that the staff at New England Wire can provide for your project. Rather than spending days or weeks researching material, electrical and mechanical properties to understand your design options and then pouring through catalogs or calling vendors to try to find a part number close to what you actually need, you can simply go to our Contact Us form to upload a document, describe your requirements, or send an image of an existing cable. Our engineering staff will use their knowledge and experience to design an ideal solution optimized for your exact application. When new requirements, additional options, or added capabilities become necessary, a custom option is quickly adaptable to your changing needs.
Every aspect of a cable is customizable. A standard product will often use coarse stranding, stiff insulation and shielding, and low temperature materials to reduce cost. In addition, the exact size, number, or composition of components needed may not be an option, limiting your selection to an oversized, overweight, or otherwise inexact solution. With a custom cable from New England Wire Technologies you can select the exact components needed for your application to minimize size and weight. We will work with you to determine appropriate conductor stranding for the level of flexibility needed and the ideal conductor material or plating option to balance conductivity, flex life, temperature rating, etc. New England Wire stocks over one hundred extrusion compounds for use as insulation and cable jacketing, combined with a variety of film and textile options to support an incredible range of product requirements. These include the specific temperature and voltage ratings required for your application, flame resistance, flexibility, biocompatibility, low smoke, chemical resistance, toughness, UV resistance, and many more. Shielding is also customizable with the proper selection of braided, spiral, foil, or a combination to balance electrical shielding effectiveness with mechanical or diameter requirements. These are just a sampling of the design options and potential advantages that a custom cable solution from New England Wire Technologies can provide.
Why a custom cable? Perhaps that is a question best answered by the thousands of satisfied customers around the world using New England Wire products. Whether it is the right option for you; that is a question we would love to help you figure out…contact us today to discuss your wire and cable needs.
Custom Braids
Insulated Braids
Flat and round braids with extruded insulations for use as ground straps and flat power leads. Typical insulation materials include PVC, TPE, Polyethylene, Polypropylene, Polyurethane, ETFE, FEP, PFA, and Silicone Rubber.
Single Thickness Braids
Non-tubular braids that are half the thickness of standard flat braids including AA59569 used in applications requiring a flat braid of minimum thickness.
Flat Wire Braids
Used for custom low-loss coaxes, miniature coaxes, and braid-reinforced tubing products, flat wire braids are typically manufactured with plated or unplated copper and various stainless steels.
Braid Reinforced Tubing
By utilizing NEWTC’s core strengths of thin walled extrusions and fine wire braiding, our subsidiary, New England Tubing, can provide custom single or multi-lumen braid reinforced tubing products that are cut to length and designed for your specific application, whether that be for medical or non-medical use. Aramid or stainless steel linear members may be incorporated to provide additional axial strength.
Endoscope and Catheter Braids
High quality stainless steel braids of various materials and tempers for use as reinforcement in endoscope body or bending section. Catheter braids are used for reinforcement by our customers that are using catheter reflow technology to manufacture catheter tubing. Variable pick braiding can also be supplied.
Textile Braids
Commonly applied over Litz wire and formed cables constructions to provide protection from abrasion, textile braids can be manufactured from various textiles such as nylon, polyester, cotton, and aramid.
Monofilament Braids
Plastic monofilament braids are used to produce low-capacitance, high-end audio cables and for mechanical protection of multi-conductor cables in lieu of an extruded jacket. Monofilament braids are also used to reinforce medical tubing products used in Magnetic Resonance Imaging (MRI) applications.
Type 7 Litz Wire
These litz wire constructions feature individually insulated wires braided together and formed into a rectangular profile. These constructions can be provided with an outer insulation of textile yarn, tape, and single or multiple-layers of extruded compounds. Learn more about Type 7 Litz constructions here.
Toll Braids
New England Wire will accept customer-supplied core for over-braiding with copper, stainless steel, copper alloys, monofilament, various textiles or other metals.
Special Configurations
These are a few of our most common braid configurations; however we are always open to discussing your specific requirements and developing a truly custom product for your application.
Flat and Wide Braids
Flat Braids
Most constructions can be supplied with textile serves or braids, tape layers or outer extruded insulations. Due to the inherent properties of braids, dimensions may vary; we manufacture to width specification. Thickness measurements are given for reference only. If your application requires a specific thickness, please consult with one of our design team members.
Extra Wide Braids
These braided constructions have widths that exceed those of standard flat braid constructions. New England Wire Technologies manufactures wide braids usually from either bare copper or tinned copper but silver plated copper, nickel plated copper, stainless steel or other metals can be utilized. A typical application for wide braids are bus bar applications where large flexible interconnects are required to withstand high currents.
Shielding Braids
These braided constructions are manufactured in tubular or oval form and are normally placed by the customer over single or multi-conductor cables in order to reduce or eliminate Radio Frequency Interference (RFI)/Electro Magnetic Interference (EMI).
Shielding braids are also commonly used as shielding for mechanical protection in single and multi-conductor cables.
New England Wire Technologies manufactures shielding braids from either bare copper, tinned copper, silver plated copper, nickel plated copper, Monel®, various stainless steels, high strength alloys or other metals.
AA59569 Braids
Federal Specification QQ-B-575C, dated September 22, 1993, was cancelled on November 20, 2000 and replaced by Commercial Item Description (CID) A-A-59569. This CID covers tinned, silver, or nickel plated copper wire braids supplied in tubular or flat form intended for use in commercial/industrial applications such as shielding over electrical conductors, controller contacts and grounding bonds.
In accordance with the specification, the wire used by New England Wire Technologies for all braid constructions conforms to ASTM B33 for tinned copper, ASTM B298 for silver plated copper, and ASTM B355 for nickel plated copper. Per the CID, all braid constructions utilizing silver plated copper meet the specs minimum plating thickness of 40 micro-inches and all constructions manufactured with nickel plated copper meet the required 50 micro-inches plating minimum thickness.
Silver plated copper is used when the shielding is to be subjected to temperatures exceeding 150° C while nickel plated copper is recommended for high temperature applications up to 400°C. Both silver and nickel plated copper offer improved corrosion resistance as compared to tinned copper.
Example of Classification/Part or Identification Number (PIN): AA59569R36T0375
