High Tensile Signal Wires
Syscom has developed insulated high tensile strength wires to overcome many issues present with using small gauge copper wire. Solid copper wire gauge 26 and smaller tends to have issues when it comes to applications involving high vibration, repetitive bending, and other high tensile strength requirements.
Due to poor flex durability and low tensile strength properties, small gauge copper has many limitations that Syscom can overcome with our Signal wire products which incorporates our industry leading metal clad fibers. With Syscom’s expertise in the conductive fibers industry, we set out to create wire products that take advantage of these lightweight and flex durability properties of high-tensile strength polymer fibers.
Applications
E-Textiles
Many E-textile applications require conductive fibers to have isolation from skin contact. Coating our traditional metal clad fibers is a great fit for this type of application and allows more design options.
Aerospace
Due to the increasing demand in the Aerospace industry for more lightweight materials, Syscom’s signal wires can be used as an alternative for small sized high tensile-strength copper wires. Our insulated signal wires can be flex-cycled by orders of magnitude more than the standard copper wiring of equivalent size and saves weight.
Industrial
In many industrial and harsh environments such as mining, the harsh and rough environments mixed with the constant vibrations would break down copper due to its weak mechanical flex durability properties. Our materials have already been proven to withstand the vibrations of mining belts and rough ecosystems. Our Lyofil product line with the insulated layer would allow for the conductive fibers to be used in harsh conditions without the loss in performance compared to its copper counterpart.
We’re Expanding Our Insulated Conductive Fiber Materials
Overall, Syscom is working to expand our product offering with new materials and insulation, if you have a question or an interest in an insulated conductive fiber, we invite you to contact us with your specific application requirements.
Conductive Fiber Hybrid Wires
Syscom has developed Fiber Hybrid Wires to overcome many issues using High Tensile Strength copper wire. Small gauge solid metal wire applications with high stress and/or repetitive bending requirements tends to need additional considerations due to its weak mechanical flex durability properties.
Hybrid wire products are a blending of solid silver plated copper wire with our conductive fibers. The result is a wire with enhanced conductivity versus standard metal clad fibers and vastly improved tensile strength when compared to solid metal wire of equivalent size.
The graphic to the right shows an example cross-section combining several of our fibers and silver plated copper wire. Using our lightweight fibers (typically Liberator or Lyofil) combined with the performance of silver plated copper wiring to create our hybrid wires.
Wires variations can be created for all sort of applications, contact us to discuss your particular requirements.
Taking Flight with Different Wings
Hybrid wire is not limited to just a few configurations of our conductive fibers and silver plated copper wire. Wire products can be designed with specific conductivity, tensile strength and flex requirements in mind. Various insulation materials such as PFA, FEP, TPU, ETFE, etc. can be applied. We invite you to read our About Syscom page to learn more about us. Also in the FAQ page, we address our more common questions