Modern Wire Wrapping Applications and Available Tools

Developed by Bell Laboratories in the 1950s, this technique involved wrapping a wire tightly around a terminal with two sharp edges (square cross-sectional area) which could form a consistent gas-tight electrical connection without soldering. With advancements in the electronic, telecommunication and aviation industries they also demanded more reliable and inexpensive means for solderless connections. Their problem was resolved perfectly by the technique now called “Wire Wrapping”. Wire wrapping is now a common method to connect signal and power terminals in today’s advanced industries.

It has been used in telephone exchanges, PCB Test Fixtures, Backplane Testers, control consoles, radios, radar, sonar, , and other complex pieces of equipment that are needed in small volumes.

Mechanical & Electrical Stability : Solderless wrapped connections have excellent mechanical and electrical stability due to their gas-tight contact area. They remain stable through exposure to severe temperature changes, humidity, corrosive atmospheres and vibration. The high shearing force of the wire at the corner of the terminal and high contact pressure remove surface contamination from the wire and the terminal, producing an intimate, clean oxidation free, metal-to-metal contact with large contact area. Initial pressure at the centre of the contact area may go as high as 100,000 psi. after the wrapping is complete cold flow causes pressure to drop to approx 30,000 psi at which point the metal stabilizes and the pressure remains constant. By bending the wire around the sharp corner of the terminal, the oxide layer on both wire and terminal is crushed or sheared, and a clean oxide-free, metal to metal contact is obtained.

Easy Removal: Although wire-wrapped connections are quick and permanent with superior mechanical and electrical qualities, they may be easily removed if necessary without damage to the terminal. To remove the connection, an unwrapping tool is placed over the terminal, engaging the first turn of the connection. Rotation of the tool removes the connection in seconds.

Types of Wraps: There are two types of wraps:

Standard Wrap – Only the bare wire is wrapped around the terminal

Modified Wrap – The first one and half to two turns (wraps) are made with the insulation wrapped around the terminal. These turns are in addition to the recommended turns (wraps) of bare wire. This wrapping process increases the ability of the connection to withstand vibration and reduced wire breakage.

For more information please log onto our site http://www.tycoproducts.co.uk and see the tools we can offer like Manual, Electric, Battery-Operated or Pneumatic wire wrap guns along with the wrapping bits and sleeves.

Resource Box: Tyco Products Limited is the UK based partner of Jonard Industries Corp is a World Class Manufacturer of Precision Hand Tools for the Telecom, Fiber Optic, wire wrapping tools, Jonard wire wrap guns, CATV, Wireless, and Electronic Industries. We are proud of our reputation, technical skills, dedication and our ability to meet the ever-increasing demands of our customers. Tyco Products Ltd is based in Reading England UK and is a reputable and reliable source for the above products.

The future of Telecommunications is Fiber Optics

Sophisticated data transfer systems now-a-days rely more and more on Fiber Optics for digital signal transmission. High Speed data transfer, highly reduced data loss, no electro-magnetic problems, small dimensions and a low weight are the main features that characterize the use of Fiber-Optic technology

There are two different materials used to fabricate optical fibers:

Polymeric fibers – short distance transfer and installations in rough surroundings.

Glass fibers – for high quality and long distance data transfer

Fiber Optics system offers data transmission rates of 100GB/sec at a bandwidth-length-product upto 1500MHz x Km

Branching to terminals is done by Plug Connectors. When processing optical fibers, it is most essential not to impair the quality of the fibers.

Tyco Products Limited offer Speciality CATV and Fiber-Optic Tools for cutting, stripping and crimping of optical fibers. We also have various Tool Kits which are a must-have for CATV and Fiber Optic Telecom Installers. They include basic necessity tools to speciality tools. Our Installers Kit TK-450 is a assembled in a convenient easy to carry Cordura case, which contains the basic services tools essential for equipment installation, repairs and cable preparations. Whether it’s Fiber optic, Coax or Copper cable, this versatile kit contains the perfect tools for today’s demanding technician. The TK-450 kit is perfect for VOIP installer. Fiber technician or communications specialist and comes with manufacturer’s Life-Time guarantee.

Tyco Products also offer a wide selection of Fiber Optic Patch Cords and Connectors used for applications such as Telecommunication, CATV, Local Networks as well as Active Device Termination. Our standard patch cords include SC, FC, ST and LC type connectors with factory tested 100% optical performance. These items have precision ceramic ferrules with endface and are compliant with JIS C-5973, IEC and Bellcore. If needed, we can also supply E2000, DIN, MU, MT-RJ and MPO connectors.

Fiber Connector Insertion and Removal tool: Tyco Products offer PCR100 which is ideal for inserting and removing small-form-factor (SFF) connectors in high density patch panels. Works with SC, SC2, MU, LC and MTRJ connectors and different cables including 2mm, 3mm, 1.6mm, jacketed and 900um buffered cables. This ergonomically designed tool is equipped with a spring loaded non-conducting material handle.

Fiber Optic Cleaning Kits: Tyco Products offer a complete Fiber Optic cleaning system with no costly re-fills or investments and in-expensive mechanisms to maintain. It delivers effective wet and dry connector cleaning .the portable cleaning system easily fits into tool kits. Includes a heavy-duty lint-free wiping material tough enough to remove buffer gel, yet soft enough for end-face cleaning. Application Areas – End face connector cleaning / Splice preparation / Buffer gel removal.

Resource Box: Tyco Products Limited is the UK based partner of Jonard Industries Corp is a World Class Manufacturer of Precision Hand Tools for the Telecom, Fiber Optic, wire wrapping tools, Jonard wire wrap guns, CATV, Wireless, and Electronic Industries. We are proud of our reputation, technical skills, dedication and our ability to meet the ever-increasing demands of our customers. Tyco Products Ltd is based in Reading England UK and is a reputable and reliable source for the above products. For more information or a quote, please visit http://www.tycoproducts.co.uk/fiber-optic-tools-html/. Tyco Products Ltd is based in Reading England UK and is a reputable and reliable source for the above products.

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