Cables are divided into round and flat types mainly to adapt to different application scenarios and technical requirements.
Round is the most common and versatile cable shape, mainly due to its physical and engineering advantages. Flat cable is designed to solve the shortcomings of round cable in certain scenarios.
Advantages and Design Principals of Round Cables:
1. Mechanical Strength and Uniformity:
A round structure distributes stress evenly across its entire circumference when subjected to forces, making it more resistant to compression, twisting, and stretching.
The conductor, insulation, filler, and jacket can be arranged concentrically within the cable, resulting in a highly stable structure.
2. Excellent Shielding:
If a shielding layer (such as a braided copper shield) is required, a round cable wrap is the most effective and uniform method, providing 360° protection against electromagnetic interference.
3. Ease of Production and Installation:
Most cable production equipment (such as extruders and cabling machines) is designed for round cable, resulting in high production efficiency.
During installation, round cables are easier to pass through **cable ducts, pipes, and glands** because they encounter no resistance during rotation.
4. Uniform Heat Dissipation:
The heat generated during power supply is evenly distributed around the cable, preventing localized overheating.
Advantages and Design Intentions of Flat Cables:
1. Space Saving:
This is their most important advantage. In confined spaces, such as undercarpets, office furniture cable ducts, laptop hinges, or tightly packed cable trays, flat cables maximize space utilization.
2. Tangle-Resistant:
Flat cables are difficult to twist or tangle, making them very convenient to store and organize. Examples include extension cables, Christmas tree light strings, and stage audio equipment cables.
3. Excellent Flexibility (Specific Directions):
When bent within a single plane, flat cables are extremely flexible and can be made with a very small bend radius. This makes them ideal for use as reciprocating cables in robotics, gantries, and mobile equipment.
4. Excellent Heat Dissipation:
Due to their flat shape, they offer a relatively large contact area with the air, resulting in improved heat dissipation. This advantage is particularly evident in applications with multiple cables connected in parallel.
5. Easy Installation and Fixing:
They can be easily secured to flat surfaces with tape, cable ties, or clips, preventing rolling, ensuring a stable and aesthetically pleasing appearance.