What are Overbraided Cables?

Meet the Connector: Overbraided Cables

Overbraiding adds an added protective layer (or layers) to cables and wire harnesses. The process of overbraiding is designed to be cost effective and versatile. It is accomplished with a wide range of fibers and different braided design configurations to best meet the demands of an application. Fine metallic strands (usually copper) are tightly woven together into a meshed, tube-like formation. The extra layer of insulation protects the cable from high temperatures, excessive abrasion, and exposure to moisture and other harmful substances such as harsh chemicals or oils.

In addition to the physical hazards cables encounter, overbraided cables offer protection from electromagnetic interference (EMI), an ongoing issue with the proliferation of connected devices in homes, workplaces, vehicles, and industrial settings. ​Overbraiding deflects EMI and RFI (radio frequency interference) and prevents the cable from transmitting EMI/RFI to other electronics.

AXOTRESS from Axon’ Cable single or double braids are designed for manual shielding over a small length of assembly branches. The optimized versions have a guaranteed transfer impedance and can be used to manufacture harnesses with improved EMC.

Design Notes 

Standards: May be RoHS-compliant; may meet VG requirements

Dimensions: Overbraided cables can be flattened to accommodate confined spaces, but they tend to be bulky.

TE Connectivity offers Raybraid and INSTALITE Lightweight Braid high performance metallic oversleeves to help provide excellent EMI shielding and lightning protection for wires and cable harness systems. The new INSTALITE Lightweight braid (LWB) offers a low cost way to save up to 50% weight over traditional braids.

Materials: Material selection is influenced by EMI requirements and temperature. Fibers used for overbraiding include fiberglass, nylon, Nomex, Kevlar, basalt, copper, stainless steel, polyester, and polypropylene. Braided wiring is often made from tinned copper or silver-plated copper, pure silver, pure nickel, nickel-plated copper, gold-plated copper, gold alloys, monel (a nickel-based alloy), or bronze.

Physical properties: Insulation and shielding

Environmental properties: Protection against abrasion, chemicals, moisture, and high temperature.

Amphenol Pcd offers overbraided cables. Braiding material for improved overall EMI performance includes stainless steel, tinned copper, and aluminum. Nylon and Nomex are used for cable jacketing and vary based on operating temperature.

Markets and Applications 

Military and Aerospace (including Marine and Space), Automotive, Transportation, Consumer

Overbraided cables are recommended for applications that subject them to low-to-medium frequencies, frequent pulling and bending, high shock or vibration, high temperatures or significant temperature changes, or short runs that require a low-resistance ground path.

Suppliers 

Axon Cable, Amphenol Pcd, TE Connectivity, , Glenair, Hellerman Tyton

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