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 https://www.tycoproducts.co.uk and see the tools we can offer like Manual, Electric, Battery-Operated or Pneumatic wire wrap tool 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 tool, 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

yco 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 tool, 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 https://www.tycoproducts.co.uk/fiber-optic-tools/. Tyco Products Ltd is based in Reading England UK and is a reputable and reliable source for the above products.

Wire Wrap Tool (or Jonard Industries Corp)

Technology has seen a boon in the last few decades. Almost all the sectors have seen an upsurge of technology and new advancements that have changed the way industries function. The telecommunication and electronics sector too has grown from strength to strength. It has seen the launch of new technologies and have helped in the development of this sector. Wire Wrap Tool are one such technology that has been able to create a considerable amount of buzz in the electronics and telecommunication sector. Wire wrap is a technology used to assemble electronics. It is used to construct circuit boards, where wires are wrapped and can produce assemblies. In telecommunications wire wrap is used in modern communications networks for cross connects between copper wiring plant. The latest and the advanced version of wire wrapping tool has been done under the label “OK Industries”. Jonard Industries Corp (USA) are a world renowned manufacturers of Precision Hand Tools, Punch down tools, Crimping tools, CATV wrenches, Wire wrapping tools for the Telecom, Computer, Military and Electronic Industries. Having it roots that date back to 1958, the company has diversified in various fields and is a well trusted name in the electronics and telecommunications sector. In February 2003 Jonard Industries acquired OK Industries and hence some of the products that Jonard now produces come under the OK label brand as well. TYCO Products is an authorized distributor for Jonard Industries Corp in the United Kingdom and sell their entire range of products and other parts of Europe as well. Some of the other products that we sell are wire wrapping tools, electric wire wrapping tool, Telecom Installers tool kit, hand wrapping, manual wire wrapping tools, adjustable precision wire strippers, Fiber Optic tools, Speciality pilers, cutters, strippers, shears and CATV tools. TYCO is a trusted name in the UK and has been dealing in wire wrap tool for long now. We have a good client base and are known for our service. We have joined hands with Jonard Industries Corp and deliver their products to the clients. JONARD’s telecommunication tools are approved by most major telephone companies in the USA & UK. The wire wrap tool have a lot of utility and used extensively in the telecommunication sector.

Tyco is authorized UK distributor for Jonard Inustries Corp (USA) and sell their entire range of products in the UK / Europe like wire wrapping tools, electric wire wrapping tool, Telecom Installers tool kit, hand wrapping, manual wire wrapping tools, adjustable precision wire strippers, Fiber Optic tools, Speciality pilers, cutters, strippers, shears and CATV tools are available with us.

Jonard Industries Corp is a World Class Manufacturer of Precision Hand Tools, Punch down tools, Crimping tools, CATV wrenches, Wire wrapping tools for the Telecom, Computer, Military and Electronic Industries. Over the years, since 1958, the company has prospered and grown their product lines which have expanded to 20 separate and unique categories of professional, highly dependable tools.

Wire Wrap Tool

The latest, most technologically advanced wire wrapping tools carry the “OK Industries” label. Jonard has the most complete line of wire wrapping and unwrapping tools for every application that calls for wire wrapping including wire stripper and cutter. Solderless connection by wire wrapping is a standard method of making connections to terminals in high density electronic equipment. Jonard wire wrapping tools offer reliability and versatility. We supply 3G wrap bit and holder, for Cut, strip and wrap operation. very popular CSW bit with Telecom Installers.

JONARD’s telecommunication tools are approved by most major telephone companies in the USA & UK

Wire wrap is a technology used to assemble electronics. It is a method to construct circuit boards without having to make a printed circuit board. Wires can be wrapped by hand or by machine, and can be hand-modified afterwards. It was popular for large-scale manufacturing in the 60s and early 70s, and continues to be used for short runs and prototypes. It is unusual among prototyping technologies in that very complex assemblies can be produced by automated equipment, and then easily repaired or modified by hand.

Wire wrap construction can produce assemblies which are more reliable than printed circuits — connections are less prone to fail due to vibration or physical stresses on the base board, and the lack of solder precludes corrosion, cold joints, dry joints, etc. The connections themselves are firmer and have lower electrical resistance due to cold welding of the wire to the terminal post at the corners.

A correctly made wire-wrap connection is seven (7) turns of wire with 1.5 turns of insulated wire at the bottom for strain relief. The square hard-gold-plated post thus forms 28 redundant contacts. The silver-plated wire coating cold-welds to the gold. If corrosion occurs, it occurs on the outside of the wire, not on the gas-tight contact, because gold is more noble than silver. A correctly designed wire-wrap tool applies up to twenty tons of force per square inch on each joint.

Wire wrap was used for assembly of high frequency prototypes and small production runs, including gigahertz microwave circuits and super computers. It is unique among automated prototyping techniques in that wire lengths can be exactly controlled, and twisted pairs or magnetically-shielded twisted quads can be routed together.

Wire wrap construction became popular around 1960 in circuit board manufacturing, and use has now sharply declined. Surface-mount technology has made the technique much less useful than in previous decades. Solderless breadboards and the decreasing cost of professionally made PCBs have nearly eliminated this technology.

In telecommunications wire wrap is in common high volume use in modern communications networks for cross connects between copper wiring plant. For example, most phone lines from the outside plant go to wire wrap panels in a central office, whether used for POTS phone service, DSL or T1 lines. Typically at a main distribution frame Internal Cross Facilities Assignments and External Cross Facilities Assignments, are connected together via jumpers that are wire wrapped. Wire wrap is popular in telecommunications since it is one of the most secure ways to attach wires, and provides excellent and consistent data layer contact. Wirewrap panels are rated for high quality data services, including Category 5 grade wiring. The principal competitor in this application is punch blocks, which are quicker but less secure.

Jonard Industries Corp is a World Class Manufacturer of Precision Hand Tools for the Telecom, Fiber Optic, CATV, Wireless, and Electronic Industries. As the company has prospered and grown, our product lines have expanded to where we now maintain 20 separate and unique categories of professional, highly dependable tools.

In February 2003 Jonard Industries acquired OK Industries and merged their operation into the “Jonard Family of Companies.” Established in 1946; OK Industries blossomed as a major force in the telecommunications and electronics industries with total dominance in the manufacture of Wire Wrapping, and Benchtop Tools including Integrated Circuit (IC) Tools, Fume Absorbers and Desoldering Pumps.

The result of this acquisition is a Global Manufacturing Powerhouse with over 100 years of combined experience.

In January 2005 Jonard Industries purchased the Cooper Hand Tools Telecom Plier Line. With this latest acquisition Jonard Industries can now claim the title as the Largest Manufacturer of Telecom Pliers in the USA.

Jonard Industries Products are used in many diversified applications. Our engineers have worked directly with our customers to develop unique Custom Products and to make our standard tools as user friendly as possible.

We work with Certified Ergonomists to design tools with worker safety in mind. Our ergonomic concentration and focus has provided us with the insights and ability to design tools that mitigate pressure on the palm, the leading cause of injuries such as carpal tunnel syndrome.