On the market, the most common type of cable is round cable, while in the shape of a different flat cable, its performance with its whether there is a difference? Each category has its own features which means that selection is very important. The purpose of this article is to point out seven distinctive features between flat and round cables with their advantages and disadvantages to help make any choice easier.
What’s the Difference Between Flat and Round Cables?
1.Physical Structure
Flat Cable: Flat cables, as the name suggests, have a flat appearance, similar to a flat ribbon. Flexible flat cables typically consist of multiple strands of fine copper wire conductors that are stranded or twisted into bundles that are arranged parallel to each other to form a flat surface. This arrangement allows flat cables to bend more with the same number of cores. Moreover, for a same number of conductor cores flat cables are superior in terms of heat dissipation as compared to round cables since the surface area is larger to help in heat dissipation.
Round cable: They have a cylindrical shape, which is the most common and traditional cable design. The wires may be arranged in a stranded fashion, where multiple strands of wire are twisted around each other to increase the flexibility and tensile strength of the cable. This construction helps reduce electromagnetic interference (EMI) and signal attenuation.
2.Flexibility and Handling
Flat cables: It makes bending in certain directions easier especially for passing through corners or into narrow areas. This type of wiring is perfect in places where space is at a premium.
Round cables: While they may be less flexible in tight spaces, they are generally easier to handle and install due to their shape. They can also be coiled more easily without causing damage.
3.Signal Quality
Round cables are often better suited for maintaining high signal integrity due to their design and materials. They typically provide superior shielding against external interference, ensuring clearer transmission of signals in data cables or audio-video applications.
Flat cables can still deliver effective signal quality, but they may be subject to more interference if not properly shielded. Consequently, if your work involves sensitive electronic applications, prioritising round cables might be beneficial to ensure optimal performance.
4. Durability and Strength
Flat cable: It may have poor durability due to lack of shielding and insulation. It may not perform well in industrial environments or in applications requiring high reliability.
Round cable: It is usually more durable and reliable, especially in demanding applications. Their construction allows them to withstand more physical stress and environmental conditions.
5. Cost
The flat cables are manufactured while taking care of the flexible as well as durable aspects such that it would already allow for bending and twisting. Because of this, they are less frequently replaced for the same function when used across many applications. Also to this problem wherein flat cables are not most originating under the carpet or abandoning or leaving them bare with no headway through the risk of damage-causing objects are balm under such cumbersome objects as carpets or into durable walls. Flat cables are therefore cheap in the long run.
Though round cables may be cheaper even at the very start, there is the problem of poor winding and burning off in a short time leading to rapid replacement at higher operational costs.
6. Maintenance
Accessing and repairing flat cables can be more complicated when problems arise, requiring additional time and resources to manage flat cables. This can lead to extended downtime and increased labor costs.
Round cables offer distinct advantages in terms of maintenance. Their round cross-section is easier to handle, making splicing or replacement simple and easy. If a part of a round cable fails, it is often easier to isolate and deal with the problem without interrupting the entire installation.
7. Application
Flat Cable Application Scenarios
- Internal connection of electronic equipment: Flat ethemnet cable can save space due to its flat structure, especially suitable for use inside electronic equipment with limited space, such as laptops, tablet PCs, smartphones, etc., the internal space of these devices is compact, and flat cables can effectively utilize the space and reduce the volume.
- Mobile electrical equipment: Flat cable has a high degree of flexibility and bending performance, applicable to the need for frequent movement of electrical equipment, such as cranes, elevators, automated production lines on the robot arm, etc., the structure of the flat cable so that it can withstand repeated bending and will not be easily damaged.
- Automotive wiring systems: The light weight and high thermal performance of flat cables play an important role in modern automotive electronic systems. For example, connecting battery modules, sensors.
- Office equipment and household appliances: The low-profile design of flat cables makes them very popular in office equipment and household appliances, such as printers and scanners. Flat cables not only save space, but also improve the aesthetics of the equipment.
Round cable application scenarios
- Industrial automation: Round cables are widely used in industrial automation, such as robots, CNC machine tools, factory automation equipment, etc. Because of their good mechanical strength and tensile properties, round cables can withstand the physical stresses in the industrial environment.
- Communication networks: Round Ethernet cables such as Cat5e or Cat6 are used for high-speed data transmission over Local Area Networks (LANs), Wide Area Networks (WANs), and internal data center connections.
- The symmetrical structure and shielding design of round cables can provide stable signal transmission and anti-interference capability.
- Outdoor and harsh environments: The thick outer jacket and waterproof performance of round cables make them suitable for use in outdoor and harsh environments, such as construction sites, oil drilling platforms, offshore wind farms, etc.
- Medical equipment: Round cables are used in medical equipment to connect various sensors, monitoring equipment and treatment instruments, such as ECG machines, ultrasound equipment, surgical robots, etc. The high signal quality and interference immunity of round cables are crucial for medical applications.
Which one fits you the best?
While it is true that flat cables offer flexibility and low costs and round cables ensure high durability packed with perfect signal quality, each type of cable has both merits and drawbacks. However, in order to make up your mind, bear in mind the individual requirements of your application such as installation space, endurance demands and aesthetics etc.
ZW CABLE is a premier cable provider. We provide guarantees for any and all aspects of the wiring orders. It can be such as flat together with twin and earth cables, twisted pair cables and NM-B Building Wire or round control cables and awg 8 solar cables. For more customization needs or related questions, please contact our representatives.
