Tinsel Wire
Tin-Plated Alloy Tinsel Wire
Alloy foil strength combined with a tin-plated, oxidation-protected surface.
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Industry application
Automotive And EV Charging
Conductors for automotive circuit electronic cables and charging pile cables, built for vibration, temperature and volume assembly.
Context
What This Industry Asks Of A Conductor
Automotive circuit electronic cables and charging pile cables are both listed among the main applications for our conductors, and automobiles are one of the fields where we help customers design conductors that set them apart. The constraints are unforgiving in a specific way: the cable has to survive vibration and temperature for the life of the vehicle, it has to be terminated at line speed by people who cannot stop to rework, and the cost has to stand up at automotive volumes. That pushes the design toward alloy foils for strength and tin plating for a surface that solders the same way on every unit.
Requirements
The Constraints That Actually Govern
Industry pain points
- Vibration and thermal cycling fatigue conductors over the vehicle's life.
- Charging cable cores need flexibility at a cross-section that would normally be stiff.
- Termination has to be repeatable at line speed with no rework budget.
- Conductor cost is under pressure at automotive volumes.
What the conductor has to deliver
- Alloy conductor strength where breaking load governs.
- Stranded construction for flexible high-cross-section cores.
- Tin plating for consistent, repeatable soldering.
- Resistance held to target across large lots.
Recommended
Conductors We Supply Into Automotive And EV Charging
Copper Stranded Wire
Copper Stranded Wire
Flexibility at full cross-section, instead of trading one for the other.
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Tinsel Wire
Copper Alloy Tinsel Wire
Alloy foil raises the mechanical ceiling over pure copper at the same construction.
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Speaker Lead Wire
Speaker Lead Wire
Built for swing performance, which is the actual failure mode in a driver lead.
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Delivery
Scenarios And Supply
Typical application scenarios
- Charging pile cable cores
- Automotive circuit electronic cable
- Automotive speaker and sensor leads
- Drag chain cable in assembly equipment
What we deliver alongside the conductor
- Sample testing on both conventional and customized products, with no minimum order quantity.
- Two production shifts running without interruption so orders leave on time.
- Technical staff available 24/7 for immediate support and engineering advice.
- A comprehensive loading report supplied with every shipment.
Process
From Your Targets To Repeat Production
1
Requirement
You send the conductor resistance, outer diameter, tensile strength, swing life and soldering method. All five are treated as one problem.
2
Material selection
Foil and base metal chosen from bare copper, oxygen-free copper and the tin-copper, iron-copper, silver-copper, nickel-chromium, nickel-iron and copper-nickel alloys.
3
Core and plating
Fiber core picked for working temperature and abrasion; tin, silver or nickel plating specified at 0.3 um to 2 um.
4
Sampling
We build and test a sample. No minimum order quantity applies to conventional or customized sampling.
5
Verification
Resistance, tensile strength and elongation are measured on our own equipment, with salt spray where corrosion matters.
6
Production and shipment
Two shifts keep delivery on schedule, and a comprehensive loading report goes out with every shipment.
Reference
Related Engineering Guides
material guide
Conductor Metals And Alloys: What We Work In And When Each One Applies
The full metal range from bare copper to constantan and graphene copper, and what each is for.
Read the guide
process guide
Plating Fine Conductors: Tin, Silver, Nickel And Why Thickness Is A Decision
What plating does for a fine conductor, how thickness is chosen between 0.3 and 2 microns, and what a good coating looks like.
Read the guide
Questions
Automotive And EV Charging: Frequently Asked Questions
Do you supply conductor for charging pile cable?
Yes. Charging pile cables are one of the listed application areas for our conductors, typically as copper stranded wire, with plating specified against the termination and environment.
Can you hold resistance across a large lot?
Conductor resistance is set as a target at the start and verified on a DC resistance tester, which measures the resistance parameters of the conductor precisely.
Building Cable For Automotive And EV Charging?
Send the performance targets your conductor has to meet. We will propose a construction and sample it with no minimum order quantity.