Cable manufacturer TST CABLES analyzes the classification, advantages, applications and technology development trends of flat cable. Help you better understand flat cables and selection and use suggestions.
Flat cables, also known as ribbon cables and flexible cables, are a special form of cable with a flat cross-section instead of the traditional round shape. This design gives flat cables unique advantages in specific applications. Flat cables are high-specification, low-resistance cable products. Due to their flat shape, they are widely used in aviation, aerospace, navigation, military and other fields. They are also suitable for large machinery and equipment, telecommunications, electronics, communications, instrumentation and other fields.
The interior of the flat cable is composed of many ultra-fine wires. Its internal structure is uniform and stable. At the same time, high-quality materials are used to ensure long-term stability of the cable performance. Its advantages include: high temperature resistance, friction resistance, corrosion resistance, and anti-interference.
The special structure of the flat cable enables it to be arranged neatly, occupying less space, and is convenient for installation, repair and maintenance. At the same time, the flat cable can also realize the connection of multi-dimensional circuits in a narrow space, greatly saving the space used by the cable.
Flat cable industry applications
Metallurgical industry: used for power connection and signal transmission of mobile devices.
Power industry: used for control systems in power plants and substations.
Petrochemical industry: suitable for environments that require chemical resistance.
Electronic industry: used for automation equipment and robotics.
Automotive manufacturing: used for mobile device connections on production lines. This article introduces the application of flat cables in the automotive field in detail. Interested friends can click to read: “Green Travel (LSZH/XLPE Cable) Automotive Cable Application“
Flat cable usage scenarios
Mobile devices: suitable for equipment that needs to be moved frequently, such as cranes, elevators, cranes, tower cranes, etc.
Indoor applications: suitable for connections between mobile mechanical parts in indoor environments.
Special environments: used in environments that require chemical corrosion resistance, waterproofing, oil resistance, and wear resistance.
Space-constrained areas: The flat design makes it easier to install in places with limited space.
Flat cable advantages
Space saving: The flat design makes them take up less space than round cables.
Easy to install: The softness and flat shape make installation more convenient.
Cost-effectiveness: Flat cables tend to be more economical compared to other cables with the same performance.
Flexibility: Flat cables excel in bending radius and are suitable for equipment that needs to be moved frequently.
Structural characteristics of flat cables
Conductors: Flat cables usually contain multiple strands of wires, which can be bare copper or tinned copper wires to enhance flexibility and extend service life.
Insulation layer: Each wire is protected by an insulation layer. Common insulation materials include PVC, rubber, etc.
Sheath layer: All insulated wires are wrapped in an outer sheath, which is usually made of PVC or rubber. Sometimes other special materials are used to meet specific needs, such as LSZH (low smoke zero halogen) materials.
Filling: In order to maintain the flat shape of the cable, some fillers may be added inside.
Performance characteristics of flat cables
Flexibility: Flat cables have good flexibility, which makes them easy to bend and install.
Environmental resistance: Flat cables can withstand harsh environmental conditions, such as heat radiation resistance, cold resistance, acid and alkali resistance, and corrosive gases.
Operating temperature range: Flat cables can operate in a wide temperature range, from -40°C to +80°C or even higher.
Electrical performance: Flat cables can maintain good electrical performance even under extreme conditions.
Flat cable safety standards and certifications
Flat cables need to comply with relevant electrical and safety standards, such as IEC (International Electrotechnical Commission) standards, as well as safety standards in other regions to ensure product quality and safety.
Common safety certifications include EN (Europe), CE (Europe), UL (USA), CAS (Canada), RoHS (Restriction of Hazardous Substances Directive), etc.
Flat cables play an important role in many industries due to their unique performance and wide applicability. If you need to select the right flat cable for a specific application, you can send an email to TST CABLES engineers to consult a customized solution.
Flat cable application examples
Automated production lines: In automated production lines such as automobile manufacturing and electronic product assembly, flat cables are used to connect various workstations to ensure efficient data transmission and power supply.
Logistics systems: In automated warehouses and logistics centers, flat cables are used to connect conveyor belts, sorting machines and other equipment to achieve fast and accurate material handling.
Entertainment facilities: In entertainment venues such as theme parks and amusement parks, flat cables are used to connect various amusement facilities to ensure the safety and experience quality of visitors.
Specific application scenarios of flat cable:
Special type flat cables
Highly flexible flat cable
Purpose: Especially suitable for applications that require frequent bending and movement, such as industrial robot arms, automated assembly lines, etc.
Features: Made of highly elastic materials to ensure durability under long-term use.
Shielded flat cable
Purpose: Used in situations where anti-interference is required, such as precision instrument control lines, data transmission lines, etc.
Features: In addition to the conventional insulation layer, it also contains a shielding layer (such as aluminum foil or metal braided mesh) to prevent electromagnetic interference.
High temperature flat cable
Purpose: Suitable for applications in high temperature environments, such as the inside of furnaces in the metallurgical industry, chemical plants, etc.
Features: High temperature resistant materials are used as insulation layers and sheath layers to ensure that the cable works normally in high temperature environments.
Underwater flat cable
Purpose: Used for connecting underwater equipment, such as underwater detectors, underwater robots, etc.
Features: Has good waterproof performance, can withstand water pressure and maintain stable electrical performance.
The production process of TST CABLES flexible flat cable is very strict and needs to go through multiple processes, including conductor manufacturing, conductor twisting, insulation manufacturing, eliminating cable strength, testing and other links.
This ensures the high quality of flat cables in all aspects of product weight, shape, conductor shape, interlayer insulation, external sheath, etc.
Flat cables have a larger capacity in a small space; flat cables are an indispensable assistant for your marine ships, aviation, military industry, machinery, medical, robots and other applications.
crane flat cable
crane flat cable is a high-performance cable, and the materials used are also very critical. Its main materials include conductors, insulation materials, shielding materials and sheath materials.
Conductor material: The conductor of the flat cable is generally made of high-purity copper or copper alloy, which can ensure the excellent conductivity of the cable. Under high temperature or special environment, the conductor material may also use specially treated conductor materials such as silver and tin plating.
Insulation material: The insulation material of the flat cable is generally made of PVC plastic (such as polyethylene, nitrile, TPE, TPEE, etc.). These materials have good electrical and mechanical properties and good insulation effect.
Shielding material: Flat cables often need shielding treatment to prevent interference signals; common metal shielding materials include aluminum foil, copper mesh, etc.
Sheath material: In cable manufacturing, in order to enhance the mechanical strength and durability of the cable, the cable also needs to be sheathed. The sheath material of the flat cable generally uses high-strength, wear-resistant and corrosion-resistant materials such as polyvinyl chloride (PVC), polyethylene, and polyurethane, which can effectively protect the internal structure of the cable.
Flat cable installation precautions
Bending radius: The minimum bending radius requirement should be followed during installation to avoid damage to the internal structure of the cable.
Fixing method: Use appropriate clamps or binding tapes to fix to avoid damage caused by too tight or too loose cables.
Environmental factors: Consider factors in the installation environment, such as temperature, humidity, chemical corrosion, etc., and choose the appropriate cable type.
Flat cable maintenance
Regular inspection: Regularly check the appearance and electrical performance of the cable to detect potential problems in a timely manner.
Cleaning and maintenance: Keep the cable surface clean to avoid dust and debris accumulation that may cause performance degradation.
Storage conditions: store unused cables properly and avoid direct sunlight, moisture and other adverse conditions.
I hope the above information can help you better understand the application and characteristics of flat cables and flexible wires and cables.
The materials used in flat cables have excellent electrical, mechanical and chemical properties, which can ensure the long-term stability of flat cables and adapt to various special working environments.
If you have a need for customized cables, need further technical support or customized flexible cables and flat cables solutions, you can visit the TST CABLES official website or send an email to the professional cable engineer of TST cable manufacturer at any time (email: lixiangchao@testeck.com, please state your country, your industry, and your required specifications and quantity in the email, we can provide free samples).
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