What are Copper Flat Wires and Reasons to use Them?

Round cables have been the natural choice for a long time, but flat cables are arising as a strong competitor nowadays. Applications, where the round cable was once a natural choice, are now getting replaced by flat cables because of being more innovative and enhanced in design.

When it comes to copper wires, they are the most trusted wires wherever there is a requirement for electrical goods manufacturing wires. The past has shown the immense usability of flat copper wire as so is the future. But mostly you would find round copper wires due to their useful geometry.

Recently it has been found that in many cases round cable geometry is not useful. To understand it in-depth, let's go through Flat vs round copper cable-

Flat vs round copper cable

A typical round cable is insulated wires that are surrounded by multiple layers of other materials. Then all these multiple layers are retained into a round profile so as to minimize the frictional heating that commonly generates while the cable moves. The outer jackets and the multi-level protection of the round copper wire protect it from the outside elements. Such cables are perfect for general use but fail to perform under specific constructions.

Due to the bundle of multiple layers, it sometimes becomes difficult for heat to dissipate. A lot of frictional heat is minimized, still, some of it is left in the repetition of cycles. Round copper wires also face the issue of electrical impedance as conductors move relative to each other.

The packaging of a flat copper wire is quite different. Conductors inside a flat copper wire are kept parallel to form a flat profile. As the conductors inside the encapsulating jacket are not moving, it makes the electrical qualities stay constant. All the conductors have the same length which minimizes the differential time between the signals.

Another good quality of flat copper wires is that they keep all the conductors isolated and stable. These, flat copper wires do not need any additional low-friction tapes or fillers. As no fillers are used further reduces both weight and volume and results in maximum packaging efficiency. The flat surface is also one of the factors for the heat to dissipate faster.

The flat wires have a thinner cross-section as compared to round wires. Due to this, they have far more inherent flexibility than the same length of round copper wires.

Additional benefits of flat copper wires

-    As flat copper wires are flat wires so they are saved from any kind of pressure. Therefore, flat cables are best suited for applications where movements are involved such as automated equipment. 

• Flat wires are more flexible and can be twisted to fit into various cross-sections. This makes flat wires best suited wherein constant flexing is required.
• Flat wires have higher tensile strength as both the insulators and conductors share the tensile loads. With flat wires, there are no installation problems or fastening issues.
• Flat copper wires take lesser spaces than round copper wires. Thus, you are left with a lot of free space.
• Flat wires also don’t need any unnecessary fillers to give them strength.
• Flat wires can also be used for multi-side forming, transformer windings, etc.

There are multiple advantages and reasons why industries are shifting from round wires to flat copper wires. At, Rajasthan Electrics Limited we have the best quality flat copper wires. Our flat copper wires are flexible enough to be installed in various locations. We take a full-time guarantee of our cables not being deteriorated whatsoever is the weather.

Apart from flat copper wires, we have an outstanding collection of PVC wires and Nickel copper wires. All of the wires are of great tensile strength and most widely applicable.