Tinsel wire
Encyclopedia
Tinsel wire is a form of low voltage electrical
wire
used when maximum mechanical flexibility is required. It is commonly found in cords used for telephone
s, especially the handset cords, and in headphones. Because of its extreme flexibility it is much more resistant to failing as a result of metal fatigue
than ordinary stranded wire or solid wire. Tinsel wire is also used in the power cable for very small appliances such as electric shavers or clocks, where stranded cable conductors of adequate mechanical size would be too stiff. "Tinsel cords" are recognized as type TPT or TST in the US and Canadian electrical codes, and are rated at 0.5 amperes.
Tinsel wire is made by wrapping several strands of thin copper
foil
around a textile
core. Because the foil is very thin, it is extremely flexible; the extreme thinness of the foil means that the minimum bend radius
imposed on the foil is many times the thickness of the foil, leading to a low probability of metal fatigue
. Meanwhile, the fabric core provides high tensile strength
.
Separated from the core, the individual foils are relatively fragile, and the textile core can be damaged by high temperatures. Together, these two factors make it difficult or impractical to terminate tinsel wire by soldering
during equipment manufacture, although soldering is possible, with some difficulty, to repair a failed connection. Although soldering may be used for emergency repairs, the foil conductors tend to break at their junction with the rigid solder. Instead, crimped connections
are commonly used. Usually the connector has a series of barbs that pierce the insulation
of the tinsel wire, allowing the connection to be made without the need to strip the insulation off the conductor.
Electricity
Electricity is a general term encompassing a variety of phenomena resulting from the presence and flow of electric charge. These include many easily recognizable phenomena, such as lightning, static electricity, and the flow of electrical current in an electrical wire...
wire
Wire
A wire is a single, usually cylindrical, flexible strand or rod of metal. Wires are used to bear mechanical loads and to carry electricity and telecommunications signals. Wire is commonly formed by drawing the metal through a hole in a die or draw plate. Standard sizes are determined by various...
used when maximum mechanical flexibility is required. It is commonly found in cords used for telephone
Telephone
The telephone , colloquially referred to as a phone, is a telecommunications device that transmits and receives sounds, usually the human voice. Telephones are a point-to-point communication system whose most basic function is to allow two people separated by large distances to talk to each other...
s, especially the handset cords, and in headphones. Because of its extreme flexibility it is much more resistant to failing as a result of metal fatigue
Fatigue (material)
'In materials science, fatigue is the progressive and localized structural damage that occurs when a material is subjected to cyclic loading. The nominal maximum stress values are less than the ultimate tensile stress limit, and may be below the yield stress limit of the material.Fatigue occurs...
than ordinary stranded wire or solid wire. Tinsel wire is also used in the power cable for very small appliances such as electric shavers or clocks, where stranded cable conductors of adequate mechanical size would be too stiff. "Tinsel cords" are recognized as type TPT or TST in the US and Canadian electrical codes, and are rated at 0.5 amperes.
Tinsel wire is made by wrapping several strands of thin copper
Copper
Copper is a chemical element with the symbol Cu and atomic number 29. It is a ductile metal with very high thermal and electrical conductivity. Pure copper is soft and malleable; an exposed surface has a reddish-orange tarnish...
foil
Metal leaf
Metal leaf, also called composition leaf or schlagmetal, is a thin foil used for decoration. Metal leaf can come in many different shades. Some metal leaf may look like gold leaf but not contain any real gold...
around a textile
Textile
A textile or cloth is a flexible woven material consisting of a network of natural or artificial fibres often referred to as thread or yarn. Yarn is produced by spinning raw fibres of wool, flax, cotton, or other material to produce long strands...
core. Because the foil is very thin, it is extremely flexible; the extreme thinness of the foil means that the minimum bend radius
Bend radius
Bend radius, which is measured to the inside curvature, is the minimum radius one can bend a pipe, tube, sheet, cable or hose without kinking it, damaging it, or shortening its life. The smaller the bend radius, the greater is the material flexibility...
imposed on the foil is many times the thickness of the foil, leading to a low probability of metal fatigue
Metal Fatigue
Metal Fatigue , is a futuristic science fiction, real-time strategy computer game developed by Zono Incorporated and published by Psygnosis and TalonSoft .-Plot:...
. Meanwhile, the fabric core provides high tensile strength
Tensile strength
Ultimate tensile strength , often shortened to tensile strength or ultimate strength, is the maximum stress that a material can withstand while being stretched or pulled before necking, which is when the specimen's cross-section starts to significantly contract...
.
Separated from the core, the individual foils are relatively fragile, and the textile core can be damaged by high temperatures. Together, these two factors make it difficult or impractical to terminate tinsel wire by soldering
Soldering
Soldering is a process in which two or more metal items are joined together by melting and flowing a filler metal into the joint, the filler metal having a lower melting point than the workpiece...
during equipment manufacture, although soldering is possible, with some difficulty, to repair a failed connection. Although soldering may be used for emergency repairs, the foil conductors tend to break at their junction with the rigid solder. Instead, crimped connections
Crimp (joining)
Crimping is joining two pieces of metal or other malleable material by deforming one or both of them to hold the other. The bend or deformity is called the crimp.- Uses :...
are commonly used. Usually the connector has a series of barbs that pierce the insulation
Electrical insulation
thumb|250px|[[Coaxial Cable]] with dielectric insulator supporting a central coreThis article refers to electrical insulation. For insulation of heat, see Thermal insulation...
of the tinsel wire, allowing the connection to be made without the need to strip the insulation off the conductor.