What Plastics Can Be Used for Wire Insulation and Cable Jacketing ?

Wire insulation and cable jacketing are essential in electrical applications, meaning that the materials used for them are crucial in ensuring the safety, performance, and durability of cables. So, what plastics can be used as insulation and jacketing materials for wires and cables?

 

Understanding Wire Insulation and Cable Jacketing

 

Definition of Wire Insulation

To make good use of wire insulation, we need to know what it is. Wire insulation is a layer of non-conductive material that surrounds a conductor. It effectively prevents leakage and protects the conductor from external environmental factors, avoiding accidents such as leakage, short circuit, and electric shock caused by contact between the internal conductor and the outside world.

Definition of Cable Jacketing

Cable jacketing is a protective layer that wraps around multiple insulated wires or cables. They are used to protect internal wires from external environmental damage, such as physical damage, moisture, chemicals, and UV radiation. Wire insulation primarily targets individual wires, while cable jacketing can protect multiple wires or cables

 

What Materials Are Used for Wire Insulation?

 

Polyvinyl Chloride (PVC)

PVC has excellent electrical properties, good flexibility, and can be used in humid environments, making it one of the most commonly used materials for wire insulation. The price of PVC is very advantageous, which is also an important reason for its widespread use.

 

 

Cross-linked Polyethylene (XLPE)

 

XLPE itself is not a plastic, but the PE rubber compound is irradiated after extrusion to cross-link its chemical molecules, making it more temperature-resistant after aging.

XLPE has extremely high heat resistance. It can withstand higher temperatures. Cables insulated with XLPE can work in an environment of 90°C for a long time. More famously, it can withstand instantaneous short-circuit temperatures of 170-250°C.

 

Polyethylene (PE)

Polyethylene is mainly divided into three categories: linear low-density polyethylene (LLDPE), low-density polyethylene (LDPE), and high-density polyethylene (HDPE). HDPE has very good strength and impact resistance, while LDPE is more prominent in flexibility and easy processability. Both are often used for wire insulation.

 

Thermoplastic Elastomer (TPE)

Thermoplastic elastomer, also known as artificial rubber or synthetic rubber, can be processed by injection molding like plastic, while being as soft as rubber. Combining the advantages of rubber and plastic, it has excellent flexibility and durability.

 

Silicone Rubber

Silicone rubber has excellent performance and can be used in extremely cold or hot environments. It provides excellent insulation as a cable insulation material. It is commonly used in demanding aerospace and high-voltage environments.

 

Teflon (PTFE)

Teflon can be used continuously in a 260°C environment, with a maximum operating temperature of 290-300°C. So far, almost no solid substances can permanently adhere to Teflon. It is non-stick, resistant to high temperatures, and has good chemical stability.

 

Fiberglass

Fiberglass has many advantages, such as strong heat resistance, good insulation and corrosion resistance, and high mechanical strength. It is commonly used in high-temperature applications.

 

 

What Materials Are Used for Cable Jacketing.

 

Polyvinyl Chloride (PVC)

PVC can be used not only for wire insulation but also for cable jacketing.

 

Low Smoke Zero Halogen (LSZH)

In the event of a fire, the burning of a large number of cables in a confined space will produce a lot of black smoke, increasing the difficulty of escape. Low Smoke Zero Halogen (LSZH) cables release minimal smoke and no halogens when exposed to fire, making them safer cables in fires and suitable for use in confined spaces such as public transportation and buildings.

 

Short forms include LSZH, LSOH, LS0H, LSFH, and OHLH

 

Polyurethane (PU)

Polyurethane has the flexibility of rubber and is more wear-resistant, making it suitable for environments prone to mechanical wear.

 

Rubber

Rubber materials are very flexible and are often used in cable jacketing. They are often seen in outdoor applications.

 

Thermoplastic Elastomer (TPE)

TPE can be used for both wire insulation and cable jacketing, offering a comprehensive service of flexibility and durability for many applications.

In summary, the safety and performance quality of electrical applications largely depend on the plastic materials used in wire insulation and cable jacketing. Understanding the characteristics of different materials allows us to quickly make the right choices based on our specific needs.