Alexei Volkov
There are many types of plastic used for wire insulation, each with its own unique properties and applications. The type of material used for wire insulation is largely determined by the application for which it is used. Some common types of plastic insulation include Polyvinyl Chloride (PVC), Polyethylene (PE), Polyurethane (PUR), and Polyvinylidene Fluoride (PVDF). Each of these plastics has different characteristics, such as flexibility, temperature resistance, and flame retardancy, making them suitable for specific applications. Other factors to consider when choosing wire insulation include electrical properties, resistance to chemicals and water, and cost.
| Characteristics | Values |
|---|---|
| Common Types | Polyvinyl Chloride (PVC), Polyethylene (PE), Polyurethane (PUR), Chlorinated Polyethylene (CPE), Polyvinylidene Fluoride (PVDF), Thermoplastic Elastomers (TPE), Polypropylene (PP), Chlorosulfonated Polyethylene (CSPE), Ethylene Propylene Diene Monomer (EPDM), Perfluoroalkoxy (PFA), Polytetrafluoroethylene (PTFE), Thermoplastic Rubber (TPR), Neoprene (Polychloroprene), Styrene Butadiene Rubber (SBR), Silicone, Fiberglass, Ethylene Propylene Rubber (EPR) |
| Temperature Range | Varies; some can withstand extreme temperatures, while others operate in a broad range of temperatures, e.g., -55°C to +105°C for PVC, -45°C to 177°C for EPDM, -65°C to 250°C for PFA, -73°C to 204°C for PTFE |
| Flexibility | Varies; some are flexible, e.g., TPE, PE, PUR, EPDM, PTFE, while others are rigid, e.g., PP |
| Resistance | Flame, moisture, abrasion, chemicals, UV radiation, wear, oils, solvents, acids, alkalis, gasoline, ozone, electrical currents, etc. |
| Application | Electrical wires, cables, plenum spaces, coaxial cables, military applications, industrial power plants, outdoor usage, etc. |
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What You'll Learn
Polyvinyl Chloride (PVC)
PVC's flexibility is below average, particularly in retractile cord applications, and it may not be ideal for environments requiring high flexibility and extended flex life at low temperatures. However, its durability and resistance to extreme temperatures make it a popular choice for wire insulation. Flexible PVC allows wires and cables to bend without breaking, while semi-rigid PVC provides enhanced abrasion resistance, heat resistance, and water resistance.
Plenum Polyvinyl Chloride (Plenum PVC) is a type of PVC insulation suitable for use in plenum spaces, such as behind dropped ceilings or raised floors, where air circulation is a factor. To be considered safe for plenum spaces, insulation must meet stringent fire safety regulations, which standard PVC does not meet.
PVC is widely used due to its balance of durability, flexibility, and cost-effectiveness. It is an ideal choice for applications where resistance to chemicals, moisture, and extreme temperatures is crucial, such as in electrical wiring and cable insulation.
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Polyvinylidene Fluoride (PVDF)
PVDF is a relatively low-cost insulation option, making it a popular choice across a wide range of industries and applications. It exhibits excellent resistance to chemicals, heat, weather, abrasion, and fire. PVDF's carbon and fluoride elemental stability contribute to its resistance, along with the polymeric integration during its processing.
The synthesis of PVDF involves the polymerization of vinylidene fluoride (VF2), which can be synthesized through a free-radical or controlled-radical process. The resulting polymer can then be processed through methods such as melt casting or solution casting. The configuration of the monomer in the chain can be either "head-to-head" or "head-to-tail."
In addition to wire insulation, PVDF finds applications in various other fields. For instance, it is used in the blades of artificial turf and as a standard binder material in the production of composite electrodes for lithium-ion batteries. PVDF's piezoelectric properties are also utilized in the manufacture of tactile sensor arrays, strain gauges, and audio transducers.
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Polyethylene (PE)
One of the key advantages of using PE insulation is its ability to transmit high-speed signals. This makes it a popular choice for cables requiring high-speed data transmission, such as those used in modern electronic devices and networks. Additionally, PE insulation is known for its durability and resistance to extreme temperatures and solvents. These properties make it a reliable option for maintaining the integrity of the insulated wires over a wide range of environmental conditions.
However, it is important to note that PE insulation is flammable. Therefore, it should be kept away from hot surfaces and potential sources of ignition to mitigate fire hazards. This consideration is crucial in maintaining the safety of the insulated wires and the surrounding environment.
In terms of flexibility, PE insulation is generally considered less flexible compared to other insulating materials. This lack of flexibility can be a factor when selecting the appropriate insulation material for specific applications that require a high degree of bending or manipulation.
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Polyurethane (PUR)
Polyurethane, also referred to as PUR, PU, and TPU, is a thermoplastic elastomer material used in wire and cable construction. It is a highly flexible compound and is typically found as a jacketing material in continuous flex applications. PUR is used as a jacketing material for retractile cords as it displays outstanding memory qualities. It is often utilized in harsh environments due to its excellent mechanical and chemical resistance properties.
PUR cables demonstrate strong chemical characteristics, including resistance to microbic decomposition. However, Polyurethane on a Polyester base will undergo a chemical reaction when exposed to warm water or tropical climates, resulting in weakened mechanical strength. In contrast, Etherpolyurethane, a type of Polyurethane on a Polyether base, exhibits superior resistance to hydrological breakdown and remains weather and ozone-resistant in all climates.
While PUR is UV resistant, it is susceptible to discolouration by sunlight, which may cause yellowing. Additionally, PUR is highly flammable and may require a flame-retardant coating for applications where fire is a concern. Despite this drawback, PUR's flexibility, durability, and ability to withstand extreme temperatures make it a popular choice for outdoor applications.
Standard voltage options for PUR wires and cables are typically 300V or 600V, although custom constructions can be designed to meet specific voltage requirements. Galaxy, a leading supplier, offers custom and stock PUR wires and cables in various AWG sizes, conductor counts, compounds, enhancements, and shielding constructions.
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Chlorinated Polyethylene (CPE)
Chlorinated polyethylene (PE-C or CPE) is a variation of polyethylene where chlorine is substituted for some of the hydrogen atoms. CPE has a chlorine content ranging from 34% to 44%. It has a soft, rubbery texture and is added to polyvinyl chloride (PVC) to increase its impact and weather resistance. CPE is also used for softening PVC foils without risking plasticizer migration.
CPE can be crosslinked with peroxides to form an elastomer used in the cable and rubber industries. When added to other polyolefins, CPE reduces their flammability. It is sometimes used in power cords as an outer jacket. CPE is non-toxic and meets environmental requirements as it does not contain heavy metals or polycyclic aromatic hydrocarbons (PAHs).
The properties of CPE depend on its chlorine content. When the chlorine content is less than 15%, CPE is a plastic. It becomes a thermoplastic elastomer with 16% to 24% chlorine content and a rubber-like elastomer with 25% to 48% chlorine. CPE is a leather-like, semi-elastic hard polymer when its chlorine content is 49% to 58%. As the chlorine content increases further to 73%, CPE becomes a brittle resin.
CPE is a cost-effective material with excellent high-temperature thermal aging resistance, especially when fabricated from low-pressure polyethylene. It is commonly produced with a density ranging from 0.93 to 0.96 g/cm3 and an average molecular weight between 5 and 25 million. CPE can be used alone or mixed with various materials, including PVC, polyethylene, and polypropylene.
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Frequently asked questions
There are several types of plastics used for wire insulation, including Polyvinyl Chloride (PVC), Polyethylene (PE), Polyester films (PET), Polyetherimide (PEI), Polyvinylidene Fluoride (PVDF), and more.
PVC is a widely used insulation material due to its cost-effectiveness, durability, and high resistance to fire and chemicals. It can maintain its shape and durability over a wide temperature range.
Polyethylene (PE) insulation is often used in coaxial and low-capacitance cables due to its excellent electrical qualities and affordability. It is more flexible than PVC and offers superior resistance to chemicals, ozone, and abrasions.
Mylar® and Melinex® are commonly used polyester films for wire insulation. Teonex® and Kaladex® are also polyester films with good mechanical properties and electrical insulation capabilities.
Yes, fluoropolymers are commonly used in wire insulation due to their resistance to bases, acids, and solvents. Examples include Perfluoroalkoxy (PFA), Polytetrafluoroethylene (PTFE), Fluorinated Ethylene Propylene (FEP), and Ethylene Tetrafluoroethylene (ETFE).
