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Tinsel wire is a type of electrical wire used for applications that require high mechanical flexibility but low
current-carrying capacity Ampacity is a portmanteau for ''ampere capacity'' defined by National Electrical Codes, in some North American countries. Ampacity is defined as the maximum current, in amperes, that a conductor can carry continuously under the conditions of use ...
. Tinsel wire is commonly used in cords of telephones, handsets,
headphones Headphones are a pair of small loudspeaker drivers worn on or around the head over a user's ears. They are electroacoustic transducers, which convert an electrical signal to a corresponding sound. Headphones let a single user listen to an au ...
, and small electrical appliances. It is far more resistant to metal fatigue failure than either
stranded wire Overhead power cabling. The conductor consists of seven strands of steel (centre, high tensile strength), surrounded by four outer layers of aluminium (high conductivity). Sample diameter 40 mm A wire is a flexible strand of metal. Wire is co ...
or
solid wire Overhead power cabling. The conductor consists of seven strands of steel (centre, high tensile strength), surrounded by four outer layers of aluminium (high conductivity). Sample diameter 40 mm A wire is a flexible strand of metal. Wire is co ...
.


Construction

Tinsel wire is produced by wrapping several strands of thin metal foil around a flexible nylon or textile core. Because the foil is very thin, the bend radius imposed on the foil is much greater than the thickness of the foil, leading to a low probability of metal fatigue. Meanwhile, the core provides high tensile strength without impairing flexibility. Typically, multiple tinsel wires are jacketed with an insulating layer to form one conductor. A cord is formed from several conductors in either a round profile or a flat cable.


Connections

Tinsel wire is commonly connected to equipment with crimped terminal lugs that pierce the insulation to make contact with the metal ribbons, rather than stripping insulation. Separated from the core, the individual ribbons are relatively fragile, and the core can be damaged by high temperatures. These 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. However, the conductors tend to break at their junction with the rigid solder.


Applications

Tinsel wires or cords are used for telephony and audio applications in which frequent bending of electric cords occurs, such as for headsets and telephone handsets. It is also used in power cords for small appliances such as electric shavers or clocks, where stranded cable conductors of adequate mechanical size would be too stiff.G. F. Moore (ed) ''Electric cables handbook third edition'',Blackwell Science,1997 , page 234 Tinsel cords are recognized as type TPT or TST in the US and Canadian electrical codes, and are rated at 0.5 amperes.


See also

*
Litz wire Litz wire is a particular type of multistrand wire or cable used in electronics to carry alternating current (AC) at radio frequencies. The wire is designed to reduce the skin effect and proximity effect losses in conductors used at frequencies ...


References

Electrical wiring Telephony equipment {{electronics-stub