History

Ropes made of multiple strands of natural fibers such as hemp, sisal, manila, and cotton have been used for millennia for hoisting and hauling. By the 19th century, deepening of mines and construction of large ships increased demand for stronger cables. Invention of improved steelmaking techniques made high quality steel available at lower cost, and so wire ropes became common in mining and other industrial applications. By the middle of the 19th century, manfacture of large submarine telegraph cables was done using machiners similar to that used for manufacture of mechanical cables.

In the 19th century and early 20th century, electrical cable was often insulated using cloth, rubber and paper. Plastic materials are generally used today, except for high reliability power cables.

Electrical cables

Electrical cables may be made more flexible by stranding the wires. In this process, smaller individual wires are twisted or braided together to produce larger wires that are more flexible than solid wires of similar size. Bunching small wires before concentric stranding adds the most flexibility. Copper wires in a cable may be bare, or they may be coated with a thin layer of another material: most often tin but sometimes gold, silver or some other material. Tin, gold, and silver are much less prone to oxidisation than copper, which may lengthen wire life, and makes soldering easier. Tight lays during stranding makes the cable extensible (CBA - as in telephone handset cords).

Cables can be securely fastened and organized, such as by using cable trees with the aid of cable ties or cable lacing. Continuous-flex or flexible cables used in moving applications within cable carriers can be secured using strain relief devices or cable ties. Copper corrodes easily and so should be layered with Lacquer.

At high frequencies, current tends to run along the surface of the conductor and avoid the core. This is known as the skin effect. It may change the relative desirability of solid versus stranded wires.

Cables and electromagnetic fields

Any current-carrying conductor, including a cable, radiates an electromagnetic field. Likewise, any conductor or cable will pick up energy from any existing electromagnetic field around it. These effects are often undesirable, in the first case amounting to unwanted transmission of energy which may adversely affect nearby equipment or other parts of the same piece of equipment; and in the second case, unwanted pickup of noise which may mask the desired signal being carried by the cable, or, if the cable is carrying power-supply or control voltages, pollute them to such an extent as to cause equipment malfunction.