Every piece of electrical equipment needs a wire coating material to stay connected and last longer.
The coating on cables helps resist electrical leakage and prevents the wire’s electric current from contacting other conductors.
It also plays a crucial role in protecting against environmental threats like water, heat, mechanical moisture and chemical issues, thus preserving the material integrity of the wire.
This article will explain everything about wire coating materials and help you choose the best one.
Wire Coating Understanding
You can prevent exposure to live wires by using a wire coating material, which prevents shock from electrical systems by grounding them.
In most cases, a wire coating will protect the conductor core without disrupting the current.
Due to its non-conductive nature, electricity traveling through one wire doesn’t interfere with that traveling through another.
In addition, a cable jacket is similar to clothing, protecting the conductor core from deterioration and ensuring no moisture, heat, chemicals, or mechanical abrasion reaches the core.
Electrical equipment cables insulators
Wire Coating Application
Many wire coating types are available to suit different protection levels, so it’s important to consider the jacket type for their applications, collectors, and environments.
For example, an extremely cold environment requires jackets that can remain flexible at low temperatures.
The cable must be made of a robust material that can withstand harsh circumstances and mechanical abrasion.
You can determine the type of material used in a wire coating.
Properties and Characteristics of the Wire Coating
| Properties | Suits industrial applications |
| Tough, tear, and abrasion resistance | Applications that require high mechanical stresses |
| Cable flexibility at low temperatures | Suitable for use in winter and arctic climates |
| Stability at a wide range of temperatures | Increased thermal performance suits various applications |
| Resistance to heat | Applications requiring long life expectancy |
| Resistance to deformation | Applications that require cables in tight spaces |
| Flame and oil resistance | Prevents the spread of fire and offers workers safety in different applications |
| Low moisture absorption | Suitable for humid environments and gives long life |
| Weather and UV resistance | Applications that require UV exposure |
| Chemical resistance | Increase the life expectancy of cable during harmful chemical exposure |
| Colors | There are specific colors on the cable that makes it easy to identify each and can also enhance the safety and appearance of the cable. |
| Elastic memory | The elastic memory feature eases the installation and handling of coil cords. |
Types of Wire Coating Materials
The two most common materials are thermoplastic and thermoset, which differs in several ways.
At high temperatures, thermoplastic materials are malleable and can melt, allowing the material to take on some toughness and flexibility once compounded.
It is also cost-effective, though there is the risk of weakening and dissolving when heated at high temperatures.
On the other hand, thermosets don’t soften after passing through high temperatures, giving them an advantage over thermoplastics, which means the material retains its “rubbery” consistency and original qualities even when heated.
Power Lines and Insulators
Wire Coating Materials
Since thermoplastics and thermosets differ in properties and applications, you must be keen when choosing.
For example, use materials with good abrasion resistance in industrial production because of their broad temperature range (-67 degrees Celsius to 392 degrees Celsius).
The most common ones are plastic, rubber, and fluoropolymers.
Plastic
Plastics are common wire-coating materials for durability, flexibility, electrical conductivity, fire resistance and excellent UV resistance.
There are many plastics used in wire coating.
Polyvinyl Chloride
PVC is a durable and cost-effective insulating material.
It exhibits high fire and chemical resistance and can maintain its shape and durability from -55℃ to 105℃.
Despite its cost-effectiveness, PVC doesn’t sacrifice flexibility or rigidity.
Plasticizers increase the cable’s flexibility and strength, making it a better choice for medical, culinary, industrial, and domestic applications.
Polyethylene
As an electrically insulating material, it is a disaster and harder plastic than PVC.
This material is used as a cable insulator or jacket because it is highly resistant to acids, solvents, and alkalis and with a high-temperature range between -65℃ and 80℃.
Polypropylene
This polymer works as an insulator and cable jacket and boasts a high-temperature range, between -30℃ and 80℃.
In addition, the thermoplastic polymer has stronger heat resistance and a tough outer shell for durability.
Nylon
It provides a flexible protective layer.
It is used in wire cutting despite having poor electrical properties and water resistance because of its durability in harsh environments.
Rubber
One thing that differentiates rubber from plastic is flexibility at low temperatures.
Rubber insulators are also resistant to high heat and moisture without breaking down.
Several types of rubber are used for wire insulation, including thermoplastic, neoprene, ethylene, and silicon rubber.
Thermoplastic rubber
TPR is a tough rubber and plasticizer blend that withstands various temperatures, UV radiation, high temperatures, bad weather, and aging.
Ethylene propylene rubber
EPR is an excellent insulator, resistant to heat, oxidation, water acids, and electrical currents.
It is a synthetic elastomer with superior thermal properties and a more compact cross-section.
You can use this wire coating material in high-voltage applications with temperatures in the -50℃ to 160℃ range.
Neoprene
Its electrical conductivity is better and exhibits superior abrasion resistance than other polymers, appealing to harsh and severe environments.
Silicone
This rubber has remained an excellent option for environments where temperatures exceed 150℃.
They exhibit high flexibility and exceptional flame retardance, with a heat resistance of up to 180℃.
As a multipurpose electrical insulator, silicone rubber is highly elastic and fits any appliance wire.
Fiberglass
With fiberglass, you have a material that can withstand extremely high temperatures, up to 480℃, making it perfect for such applications as mining, energy, military, and oil sectors.
Also, fiberglass has excellent resistance properties against chemicals and water.
Electrical equipment cables insulators
Fluoropolymer
Fluoropolymers resist bases, acids, and solvents in high-temperature and severe chemical conditions.
They can also be used as cable insulators due to their exceptional electric-resistant qualities.
Polytetrafluoroethylene
PTFE offers exemption from or resistance to fire, UV, chemicals, heat, and moisture.
Also, it is one of the most highly flexible materials with a temperature range of -60 ℃ to 200℃, making it perfect for a wide range of applications.
Fluorinated ethylene-propylene
FEP has excellent electrical insulation properties and chemical resistance.
It is also durable and will work in different temperatures, ranging from -80℃ to 200℃, without losing flexibility.
You can use it in the chemical, aviation, medical, electronic, and aerospace industries.
Ethylene tetrafluoroethylene
ETFE exhibits excellent corrosion resistance and a high melting temperature.
It also has superior resistance to chemicals, electrical currents, and high-energy radiation.
It is commonly used in telecommunication to improve data transmission.
Perfluoroalkoxy
PFA materials have a low dissipation factor that enhances electrical efficiency.
Most PFA wires use less power, making them prevalent in the military, aerospace, and oil/gas sectors.
They have a temperature range of -65℃ to 250℃.
The material is also highly insulated against fire, chemicals, and UV light.
TPE insulation
Like other fluoropolymers, TPE insulation is flame redundant and flexible.
You will likely find TPE insulation in robotics, automobiles, and healthcare, where temperatures range between -50℃ to 105℃.
With this material, you don’t have to worry about molding, extrusion, or flexibility issues.
Conclusion
Choose the right jacketing material if you want your wires and cables to function at their best in any setting.
Key factors include operating temperature, fire resistance, ultraviolet light resistance, flexibility, durability, and chemical resistance.
These elements can make or break your project, so research and choose wisely.