Tinsel Wire
Tin-Plated Tinsel Wire
Tin layer protects the copper foil surface from oxidation through storage and handling.
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Industry application
Consumer Electronics Cables
Fine conductors for mobile devices, earphones and consumer cable assemblies built in high volume.
Context
What This Industry Asks Of A Conductor
Consumer electronics cables are one of the main application areas for our conductors, and they carry a particular combination of constraints: very small outer diameters, a resistance the circuit will not negotiate on, a flex life set by how people actually treat their devices, and an assembly process running at a volume where a percentage point of solder defects is expensive. Mobile device and in-ear monitor are both listed application areas for our conductors, and the work is the same in each: fit the conductor inside the diameter, hit the resistance, and make the termination boring.
Requirements
The Constraints That Actually Govern
Industry pain points
- Outer diameter is capped by the connector and the housing.
- Resistance targets do not move even as diameter shrinks.
- Users flex cables in ways no lab test fully predicts.
- Solder defects at consumer volumes are costly to rework.
What the conductor has to deliver
- Very fine conductors that still meet a resistance figure.
- Multi-layer foil construction to cut resistance without added diameter.
- Plating that gives consistent solder wetting on the line.
- Shielding that does not stiffen a thin cable.
Recommended
Conductors We Supply Into Consumer Electronics Cables
Precision Copper Foil
Precision Copper Foil
Extremely fine gauges produced for winding at 0.04 mm to 0.40 mm conductor diameters.
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Tinsel Wire
Bare Copper Tinsel Wire
Highest conductivity per unit of foil in the range, with no plating layer in the current path.
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Precision Copper Foil
Braided Shielding Sleeve
Shielding and mechanical protection without stiffening the cable.
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Delivery
Scenarios And Supply
Typical application scenarios
- Mobile device internal cable
- Earphone and in-ear monitor cable
- Consumer cable assemblies
- Shielded thin cable constructions
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
technical guide
What Tinsel Wire Is, And Why It Outlasts Solid Wire Where Cables Bend
The construction, the materials and the reason a foil-over-fiber conductor beats a solid wire of the same size on flex life.
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
Consumer Electronics Cables: Frequently Asked Questions
How do you lower resistance without increasing diameter?
With the multi-layer copper foil design and multi-strand twisting. Both significantly reduce conductor resistance, and they improve breaking load and swing performance at the same time.
What is the smallest conductor you make?
A single tinsel wire can go down to 0.04 mm outer diameter, with single-layer or multi-layer copper foil structure.
Building Cable For Consumer Electronics Cables?
Send the performance targets your conductor has to meet. We will propose a construction and sample it with no minimum order quantity.