Cables and wires play an important role in electronic and electrical systems and devices. But they should properly be built to transmit electrical signals and power correctly. Among the key components, which must be put into consideration when choosing or manufacturing custom design cables or wires is insulation.
What is Cable and Wire Insulation?
It refers to a non-conductive material in the construction of cables and wires. Commonly, it is referred to as a dielectric when talking of RF cables. The effectiveness and longevity of wires depend on the insulation type used. Insulation and dielectric materials help to preserve the integrity of the wire material by protecting wires and cables against environmental threats and hazards, like physical, chemical, water, and heat damage. In addition, wire insulation resists electrical leakage that prevents electrical current in the wire from getting into contact with different other cables and wires, which are nearby.
Why Use Insulated Wires and Cables?
One of the obvious benefits of insulated wires and cables is the color. Although this might seem simple, it matters a lot, especially in very sophisticated applications of wires and cables. Colored insulation helps to determine the key difference between cables and wires when many of them run together.
Other reasons for using insulated wire and cables include:
- Protection from short circuits
- Code Compliance
- Improved efficiency and performance
- Durability & protection from environmental factors
- Electrical safety
- Electrical noise reduction
- Thermal insulation
Forms
Manufacturers use different materials to insulate their wires and cables. This is why you will find different types of insulated wires and cables in the market. Some of the common types you will find include:
1. Plastic Insulation
A good example of plastic insulation is PVC (polyvinyl chloride), which is commonly used for its various applications. With the temperature ranging between -55 degrees Celsius and 105 degrees Celsius, this type is abrasion, flame, and moisture-resistant insulated wire. The applications of this type are compatible with solvents, acids, ozone, and gasoline, making it safer for food and medical-related purposes.
2. Fluoropolymer
This is a polymer, which is resistant to solvents, bases, and acids. It is popular in insulating electrical cables and wires. Good examples include polytetrafluoroethylene, perfluoroalkoxy, and fluorinated ethylene propylene.
3. Nylon Insulation
This type of insulated wire and cable has exceptional abrasion, chemical, and cut-through resistance. It is very flexible and extruded over soft insulating materials. In addition, nylon is a very strong material but has a weak moisture penetration that lowers the overall electrical properties.
4. Thermosetting Insulation
Well, thermosetting compounds include polymer resins, which undergo an irreversible process of curing, like vulcanization through heat, so as to form a rubber or plastic-like material. The most commonly used thermosetting materials of insulation for cables and wires include EPR (ethylene propylene rubber) and XLPE (cross-linked polyethylene).
The bottom line is that there are different kinds of insulation, all with their own functions and some with similar traits. Therefore, when choosing the right kind of wire and cable insulation for your application, it would be best to consider durability and the amount of protection it offers.
