The outer protective layer of either insulation or cable core comes in different sheath types that perform different functions. Braid sheaths are not left out as they have special functions. So is it better to use a braided cable? What are the outstanding advantages? Next, we will explain the concept of braided materials in cables and their advantages in wires and cables applications.
What is Braided Wire?
Essentially, braided wire is made up of multiple strands of wire that are woven together to form a flexible yet strong structure. The unique structure allows it to withstand physical stress and resist damage such as cuts or abrasions. We can find various types of braids in braided wire, each serving different purposes. Some common types include:
- Flat Braids: Often used in grounding applications.
- Tubular Braids: Perfect for shielding cables.
- Round Braids: Commonly used in flexible connections.
Materials Used in Braided Wire
According to the braided cable sleeve material to classify, the wire and cable braiding type can be divided into fiber braiding, metal braiding and mixed braiding three types.
Fiber braiding has a lightweight, soft and good insulation properties. Commonly used fibers include natural cotton, hemp and synthetic nylon, polyester and aramid. Fiber braid can effectively prevent physical damage to the internal wire, while providing the necessary flexibility to provide safe and reliable electrical connections.
The main role of metal braid is to protect the signal inside the cable from external electromagnetic interference and also to prevent the electromagnetic signal generated inside from interfering with the outside. Commonly used metal wires for metal braiding include soft round copper wire, tinned soft round copper wire and galvanized steel wire. Metal braiding can not only withstand the effects of large mechanical forces, but also anti-electromagnetic interference shielding, such as copper wire braided control cables.
Hybrid braiding refers to a form of braiding in which two different materials are crossed. For example, nylon fibers are used to enhance the flexibility and tensile strength of a metallic braid while maintaining good electrical conductivity.
The outstanding advantages of braided cables
The advantages of braided cables are obvious when comparing them to solid and stranded cables. Solid wire consists of a single piece of metal that is rigid but lacks flexibility. Whereas stranded wire is made up of multiple strands of wire, it is more flexible than solid wire, but not as flexible as braided cable. Braided cable combines flexibility and strength with resistance to kinking and twisting for durability. However, the advantages of braided cables do not end there.
“Reduced”Interference
When electronic equipment is in operation, rapid changes in current generate a changing magnetic field around the wire, which in turn propagates through the air or other media, creating electromagnetic waves. For example, switching power supplies, motors, radio transmitting equipment, etc. can be a source of radiation interference. The mesh structure of braided signal cables can effectively reflect and absorb the surrounding electromagnetic waves, thus reducing the interference of external electromagnetic fields on internal signals. Its excellent EMI and RFI shielding capability guarantees signal integrity.
“Enhanced” Performance
In addition to its physical properties, braided wire offers excellent electrical performance. Braided wire has excellent electrical conductivity. The braided construction creates a larger cross-section, which reduces resistance. This means that electricity flows through the braid more efficiently, making it an excellent choice for high-performance applications. There is also an open braid construction that allows for rapid evaporation of moisture, preventing damage to the internal cable from water buildup, while helping to dissipate heat and reduce electrical failures caused by overheating.
When Should You Opt for Braided Wire?
Industrial
Aerospace
Aerospace systems require components that can withstand extreme conditions. Braid meets these requirements by providing excellent electromagnetic interference (EMI) shielding. In addition, braid’s light weight contributes to overall efficiency.
Automotive
In the automotive industry, braided cables are used in vehicle electrical systems to help increase availability and reduce the need for maintenance, ensuring stable operation over long periods of time. In addition, the durability of braid means it can withstand the constant vibration and temperature fluctuations typical of the automotive environment.
Consumer Electronics
Braid is not just for heavy-duty industrial use. It also enhances the performance and durability of consumer electronics.
Audio Equipment
The use of braided cables in audio equipment helps to improve sound quality, reduce noise interference and provide a clearer, purer audio experience.
Computer Cables
In computer cables, braided cables are preferred for connecting peripheral devices due to their resistance to interference and abrasion, ensuring that the devices provide stable, fast performance even under high-frequency use. e.g. CAT5e、CAT6.
Selection and Installation Tips
Braided Wire Uses. Different applications require different types of braided wire. For example, if you work with aerospace systems, you’ll need wire that provides excellent electromagnetic interference (EMI) shielding and can withstand extreme conditions. By contrast, for audio equipment, you might prioritize flexibility and conductivity.
Braided cable usage environment. Will it be exposed to moisture, chemicals, or extreme temperatures? If so, you may want to choose a material like tinned copper, which offers additional protection against corrosion.
Installing braided wire correctly is just as important as choosing the right type.
- Avoid excessive bending or twisting, as this can damage the braided wire.
- Use proper connectors or shielded grounding at the connections of shielded braided cables to maintain good electromagnetic shielding.
- Use proper tools to cut and strip cables to ensure that the edges are neat and will not fray.
- Keep cables away from heat generating equipment to avoid damage to the insulation due to overheating.
If better shielding is needed, we can still enhance it in different ways. For example, increase the density of the weave. The higher the density of the weave layer, the fewer the gaps, the better the ability to block and absorb electromagnetic waves. Increasing the coverage area by using finer braided wires or adjusting the braiding process can achieve a shielding effect of -75dB to -100dB.
Multi-layer shielding is also available. Multi-layer shielding structures combining metallic foils and woven wire mesh can complement the limitations of each other. The foil provides near 100% coverage, while the braid provides a low impedance ground path.
High-Quality Braided Wire Solutions – ZW CABLE
When you’re in the market for wire for next project, remember that quality counts, especially if you’re looking for long-lasting results. ZW CABLE braided electrical wires are built to last, making them the best choice for both large projects and small home improvement tasks.
For customized requests for braided cable materials or for more power cable types, please feel free to contact our representatives!
