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How to Make a Coil Cable

A coiled cable makes the connection of two electronic or power devices so much easier. The benefits of a coil cable are numerous, but the main purpose is so that a big pile of excess cable doesn’t lie around and get tangled in the floor.  A retractable cable can also be called a coil cord, coil cablecoiled cord, curly cord, coiled cable, retractable cord, spiral cable or spiral cord to name just a few other names. All these names are used in this article, but they all mean the same product.

How to make a coiled cable?

It is always best to consult with experts like Coil Cable Specialist LLC.

First Step is to make a cable. This can be as simple as one conductor or more. That coiled cable has 4 conductors; 16 AWG (AWG stands for gauge). Most coiled cables are not too easy, they're more complicated, but Coil Cable Specialist LLC can do them all kinds of retractable cords.

Since a spiral cable acts as a spring it is critical when making the cable that all the conductors are constructed right, it's very important to back neutralize the wires when twisting. Things to consider are the size of the conductor stranding, the twist of the stranding, the direction in which the conductors are bundled and the insulation material used.

The final cable consideration is the outside jacket material. This is critical because this is where most of the “coil” action in a coiled cable occurs.  Coil Cable Specialist LLC uses the following materials; polyurethane (PU), thermoplastic elastomer and polyvinyl chloride (PVC). Each material has applications it is suited for and these can range from medical uses to high-end industrial control systems.

Second Step is to wind the cable onto a rod. During this process, the coil cable starts to look like the final product. The cable is wrapped around a rod they can be small as 1/4 of an inch to a large as 15 inches in diameter. The size of the rod creates the inside diameter of the coil cord.  A small rod creates a coil cable with more spring action and a larger rod creates less spring action.

Third Step is heat treating. Since the outer jacket material is thermoplastic it can be softened with heat. However, too much heat will melt the material and too little won’t change anything. The goal is to heat the material JUST hot enough and for JUST the right amount of time to get it to stay in the coiled shape. This requires some experience and know how because if it isn’t done right then the retractable cord won’t perform correctly.

 STEP FOUR is reverse winding.  During heat treating the material on the outside of the coil cord is lengthened and the material on the inside is shortened.  When the coil cord is reversed or turned inside out, the force pulls the coils together giving the coil cord the spring action. 

In making a coil cable there are a lot of details that need to be considered. A few things to consider are how many cycles will the coil cable experience, what kinds of environment will the curly cord endure and what electrical properties are vital for proper performance. Coil Cable Specialist LLC has the experience to talk you through the design considerations and show you how a quality coiled cable performs.

Call, contact form or email us and we will be happy to design your next coil cable.