Choosing a Conductor Material for Your Custom Cable
If you are designing a cable for a custom application, then one of the most important choices that you will make is the conductor type. The conductor is the metal that will allow for the flow of electrical current from one end of the cable to the other and is ultimately responsible for the transmission of your data or signal. Although you should work with a professional electrical engineer to finalize the details of your cable, it is helpful to have a basic understanding of the options that are available to.
Conductors 101
Although the physics that govern electrical current can be extremely complex, conductors are fairly straightforward in principle. A conductor is simply a material where electrons are not tightly bound to the individual metal atoms and can flow freely. This electron flow is what creates an electric current, which is simply the movement of electric charge from one location to another. When designing a cable, the choice of metal to use as a conductor is one of several design decisions that will influence the cable's ability to carry current from one point to another.
Solid vs. Stranded
Cable conductors come in two varieties: solid and stranded. Solid conductors are, as the name implies, a single piece of solid metal. Stranded conductors consist of many smaller pieces of metal that are stranded together in one of several different configurations. The choice between a solid or stranded conductor configuration will generally be determined by your need for durability vs. flexibility.
Stranded conductors are potentially less durable and there is a greater likelihood of individual strands breaking over time, but they offer a great deal of flexibility. This is particularly useful if the cable will be often connected and disconnected or moved from location to location. On the other hand, solid conductors are more prone to breakage when bent or twisted, but they offer significantly more long-term durability if they will be left in a single place for a long period of time. This trade-off is why most consumer cables are stranded while electrical cables used in structures are often solid core.
Copper vs. Alloys
Copper is the most commonly used conductor metal, and it is suitable for most types of cables. Copper's conductivity is higher than any other economically viable material, and so it is generally used for all but highly specialized applications. In addition to its high electrical conductivity, copper offers excellent corrosion resistance as well as good thermal conductivity and durability. Copper is also a cost-effective material, making it a good choice even when budget constraints are tight.
Alternatives to copper are generally chosen for applications with very specific needs. In particular, if a copper cable is too heavy, then copper alloys can be used instead. These alloys will not necessarily offer the full range of benefits as copper or the same electrical conductivity, but they can be useful in cases where other factors (such as conductor weight or size) are more important.
Speak to an industrial equipment supplier, such as Beach Wire & Cable, for more information.
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