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Groups Of Cable Insulations
The three most popular groups of insulating materials for cables are thermoset, thermoplastic, and fluoropolymer. Let's look into their main properties.
Thermoplastic Insulations
Are polymers that can be heated and cooled multiple times without altering their chemical properties. This makes them highly versatile and recyclable. However, they typically have lower heat resistance compared to thermosets and fluoropolymers. Thermoplastic is a costeffective material for various residential, commercial, and industrial applications.
Thermoset Insulation
Are polymers which cannot be remelted or reformed once cured This makes them extremely heat resistant and less likely to deform under load at high temperatures However, it also means they cannot be recycled in the same way as thermoplastics These insulations are suitable for high-voltage cables and harsh environments
Fluoropolymer Insulations
is a type of polymer that contains fluorine atoms in their chemical structure. Fluorine gives these polymers exceptional resistance to heat, chemicals, and electrical conductivity. As such, they are often used in highperformance applications, such as aerospace and industrial equipment.
CHAPTER II
Types of Thermoplastic Insulations
1.Polyvinyl Chloride (PVC):
Characteristics: Good insulator, flexible, flame-resistant, costeffective resistant to oxidation and degradation. One of the most popular insulations on the market. SR-PVC is the version with improved abrasion resistance.
Temperature Rating: Up to 105°C.
Applications: Used in residential, commercial, medical,and industrial wiring.
2.Polyethylene (PE):
Characteristics: Excellent electrical properties, high-insulating capacity, moisture resistant Not for high temperatures and outside applications Can be low-density or high-density A low-density one is more flexible
Temperature Rating: Up to 80°C
Applications: Used in low voltage applications, coaxial cable, and Ethernet cables
3.Nylon (polyamide):
Characteristics: Good toughness, abrasion-resistant, chemically resistant, good dielectric properties. Resistant to cut-through.
Temperature Rating: Up to 105°C.
Applications: Often used in THHN building wire as a protective outer cover over the PVC insulation. Most often used as a jacket. Used in automotive wire and appliance wiring.
4.Thermoplastic
Characteristics: High abrasion resistance, good flexibility at low temperatures, excellent tear strength, and resistance to oil, grease, and various solvents.
Temperature Rating: Up to 125°C.
Applications: Widely used in robotic and automation cables, industrial applications, and cables requiring superior abrasion resistance.
5.Polypropylene (PP):
Characteristics: A thermoplastic polymer has excellent chemical resistance, low dielectric constant, lower heat resistance than PE.
Temperature Rating: Up to 105°C.
Applications: Mostly used in telecommunications, low voltage cables, and radio frequency signal transmission.
6.Polystyrene (PS):
Characteristics: Low-cost, good dielectric properties, brittle
Temperature Rating: Up to 75°C
Applications: Used in capacitors, cable spacers, and insulating panels
8.Polycarbonate (PC):
Characteristics: High strength, excellent heat resistance, and good electrical properties. It's also transparent.
Temperature Rating: Up to 125°C.
Applications: Used in connectors, fiber optics, and other hightemperature applications.
CHAPTER III
Types of Thermoset Insulations
1.Cross-Linked Polyethylene (XLPE):
Characteristics: High dielectric strength, chemically stable, moisture resistant, excellent resistance to most solvents, and has better heat resistance than PE.
Temperature Rating: Up to 90°C for normal operation, 130°C for emergency overload conditions, and 250°C for short-circuit conditions.
Applications: Used in power cables, control cables, and applications where heat resistance and mechanical strength are important.
2.Ethylene Propylene Rubber (EPR):
Characteristics: Excellent dielectric strength, flexibility, good resistance to heat, oxidation, ozone, and weather, and a wide operating temperature range
Temperature Rating: Up to 90°C
Applications: Widely used in MV and HV cables, mining applications, and flexible cords
3.Silicone Rubber:
Characteristics: Very common insulators good at high temperatures, flexibility, good electrical properties, resistance to weather, ozone, and UV light.
Temperature Rating: Up to 180°C.
Applications: Used in appliance wiring, automotive wiring, and medical applications.
4.Neoprene:
Characteristics: Good flame retardant properties, excellent physical toughness, and resistance to oil, ozone, and oxidation
Temperature Rating: Up to 90°C
Applications: Used in mining cables, portable power cables, and other heavy-duty applications
5.Chlorosulfonated Polyethylene (CSPE or Hypalon):
Characteristics: Outstanding resistance to ozone, oxidizing chemicals, oils, and flame spread Good physical properties and color stability
Temperature Rating: Up to 90°C.
Applications: Used in control cables and power cables, especially for outdoor applications due to their superior weather resistance
5.Polyurethane (PUR):
Characteristics: This polymer has excellent resistance to abrasion, oil, and ozone, good flexibility at low temperatures.
Temperature Rating: Up to 80°C.
Applications: Used in robotic and automation cables, coil cords, and other applications requiring high flexibility and toughness.
6.Silicone:
Characteristics: Excellent flexibility at low temperatures, good heat resistance, good electrical properties
Temperature Rating: Up to 180°C, some special types can withstand up to 250°C
Applications: Used in cooking appliances, medical devices, and other applications requiring high heat resistance and flexibility
CHAPTER IV
Types of Fluoropolymer Insulations
1.Polytetrafluoroethylene (PTFE/ Teflon):
Characteristics: Exceptional resistance to heat, chemicals, and electrical interference.
Temperature Rating: Up to 260°C.
Applications: Used in aerospace, telecommunications, computer wiring, and military applications.
2.Fluorinated Ethylene Propylene (FEP):
Characteristics: Similar to PTFE but with lower heat resistance and slightly different electrical properties. Excellent resistance to chemical attack.
Temperature Rating: Up to 200°C.
Applications: Used in data communication and instrumentation cables.
3.Ethylene Tetrafluoroethylene (ETFE):
Characteristics: Excellent resistance to heat, radiation, and chemical attack, good electrical properties
Temperature Rating: Up to 150°C
Applications: Used in aerospace and solar cell applications
4.Polyvinylidene Fluoride (PVDF/ Kynar):
Characteristics: Excellent resistance to abrasion and impact, good resistance to most chemicals and UV radiation, good flame and smoke properties.
Temperature Rating: Up to 150°C.
Applications: Used in plenum cables, aerospace, and other highperformance applications.
5.Polyvinyl Fluoride (PVF):
Characteristics: Excellent resistance to heat, radiation, and chemical attack, good electrical properties
Temperature Rating: Up to 150°C
Applications: Used in aerospace and solar cell applications
6.Perfluoroalkoxy Alkane (PFA):
Characteristics: Excellent heat resistance, chemical inertness, and electrical properties. It's very similar to PTFE and FEP but with better heat resistance.
Temperature Rating: Up to 260°C.
Applications: Used in hightemperature, high-frequency applications such as computer wiring, medical equipment, and aerospace applications.
7.Ethylene Chlorotrifluoroethylene (ECTFE):
Characteristics: High mechanical strength, excellent chemical resistance, good electrical properties.
Temperature Rating: Up to 150°C.
Applications: Used in aerospace and chemical processing industries for wire and cable insulation.
8.Perfluoroalkoxy Alkane (PFA):
Characteristics: Very similar to PTFE in terms of its excellent resistance to heat, chemicals, and electrical interference, but with better mechanical properties.
Temperature Rating: Up to 260°C.
Applications: Used in hightemperature, high-corrosion applications, such as semiconductor manufacturing, aerospace, and chemical processing industries.
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