Electrical Wire Insulation and Cable Jacketing

Polyvinyl Chloride (PVC)

Polyvinyl Chloride is one of the most widely produced synthetic plastic polymers. PVC is generally available in both rigid and flexible forms. The rigid form of PVC (sometimes referred to as RPVC) is used in the manufacturing of pipes for plumbing, doors, and windows used in the construction industry, and even commercially in the manufacturing of credit cards, bottles and certain packaging.

For PVC to be suitable for use in the insulation and jacketing of wire and cable, plasticizers are added to the polymer to make it softer, more flexible and easier to extrude. A semi-rigid PVC (SRPVC) is also available where additional flexibility is desired. PVC is safe for use in medical and food-related purposes as it is odorless, tasteless, and non-toxic. 

Performance of Polyvinyl Chloride (PVC) for Wire and Cable Insulation and Jacketing

Polyvinyl Chloride (PVC) is suitable for both wire insulation and final cable jacketing.

Polyethylene (PE)

Polyethylene (PE) is primarily used in the packaging industry in the manufacturing of plastic milk and water jugs, detergent and shampoo bottles, and some plastic bags. As a wire and cable insulator and jacketing material, polyethylene is mixed with additives to make it softer and more flexible. 

The most common form of PE is solid (non-foamed). Medium-density polyethylene (MDPE), a foamed version of PE, is also available and offers a lower dielectric constant than its solid counterpart. Solid PE carries a low flexibility value, which can vary depending on the density used. Use of High-density polyethylene (HDPE) will further reduce flexibility while Low-density polyethylene (LDPE) tends to increase flexibility. In addition, Polyethylene can be cross-linked to increase its resistance to cracking, cut-through, soldering, and solvents.

Performance of Polyethylene (PE) for Wire and Cable Insulation and Jacketing

Polyethylene is suitable for both wire insulation and final cable jacketing.

Polypropylene (PP)

Polypropylene (PP) is in many aspects similar to polyethylene in both physical and electrical characteristics, but with improved thermal properties. Polypropylene is reasonably economical and can also be foamed to improve its electrical properties.

Polypropylene is susceptible to degradation from exposure to heat and UV radiation and is therefore not recommended for outdoor applications where exposure to sunlight is likely. Use of polypropylene as an insulation material for thin walls is typical within the wire and cable industry with an alternative material used as the final jacket.   

Performance of Polypropylene (PP) for Wire and Cable Insulation and Jacketing

Polyethylene is suitable for both wire insulation and final cable jacketing.

Polyurethane (PUR)

Polyurethanes (PUR) are highly desirable polymers for their ruggedness, durability, and flexibility, but also for their ability to be foamed. PUR provides stability and long life, superior dielectric properties, and are resistant to high temperatures and moisture.  Polyurethanes are used in manufacturing a broad range of products across multiple applications including marine, automotive, military, industrial and communications.

Polyurethane is a highly flammable material and while a flame retardant version is available (7R Option), it comes at the sacrifice of strength and surface finish. Polyurethane has poor electrical properties, which make it more suitable for use as a final jacket.

Performance of Polyurethane (PUR) for Wire and Cable Insulation and Jacketing

Polyurethane is not recommended as an insulator. It is mostly suitable for final cable jacketing.

Chlorinated Polyethylene (CPE)

Because of its resistance to oil, heat, flame, and its durability against the elements, chlorinated polyethylene (CPE) is typically used to insulate wire and control cables for industrial power plant applications, appliance wire, lead wire, coil leads, transformer leads, and motor lead wire.

CPE can often serve as a lower cost, more environmentally friendly alternative to chlorosulfonated polyethylene while matching chemical, flame and UV resistance.

Performance of Chlorinated Polyethylene (CPE) for Wire and Cable Insulation and Jacketing

Chlorinated Polyethylene is suitable for both wire insulation and final cable jacketing.

Nylon

Nylon refers to a group of plastics known as polyamides. Nylon is extremely flexible and serves as tough insulation –  exhibiting strong abrasion, cut-through, and chemical resistance. Nylon can be extruded over softer insulation compounds to provide an extra layer of protection against moisture, increase impact resistance, and protect against high wear.

Performance of Nylon for Wire and Cable Insulation and Jacketing

Nylon is suitable for both wire insulation and final cable jacketing.