What Makes Each Cable Jacket Material Different?
Next to the shielding, a cable is surrounded by a very important outer jacket. This outer jacket is made from different materials depending upon your application, and the different jacket materials protect against issues such as mechanical stress, temperature or chemical substances.
What are the different cable jacket materials?
Different applications require unique resistances and protections, so cable manufacturers offer a selection of jacket materials that are produced from various material mixtures. Based upon the jacket material chosen, this outer jacket can have very different properties when facing external conditions and environments.
PVC
PVC or polyvinyl chloride is a very versatile thermoplastic. Due to its chemical structure and flame resistance, it is often used within assembly lines, packaging, and lighting technologies. PVC cable jacket is popular because of its high strength and strong insulating properties. The material is also resistant to permanent moisture and salt water. However, in the event of a fire, properties such as chlorine (a halogen) are released from a PVC cable, which can pose a danger to humans since they react with water.
In the low voltage range (up to 1,000 V), polyvinyl chloride is also known as the material with the best price-to-performance ratio. igus® offers PVC jacketed cables in a non-oil-resistant and oil-resistant mixture.
PUR
PUR or polyurethane, on the other hand, is a halogen-free and self-extinguishing thermoplastic elastomer that has become increasingly important in regard to cable jackets in recent years. The primary strengths of PUR jacket material are notch-resistance and flexibility even at low temperatures. However, at high temperatures, PUR can become very rubber-like, leading to higher abrasion within the chain in contrast to the other two materials.
PUR has better chemical compatibility than other materials, which makes them resistant to oil and coolants. Additionally, due to their composition, they do not contain any toxic halogens that could escape in the event of a fire. Pipes made of PUR are popular for machine tools, in plant construction, at cement plants, in the paint industry, and in the automotive industry, which is why igus® offers a wide range of cable types with PUR jackets.
TPE
TPE stands for thermoplastic elastomers and is the generic term for a variety of subcategories. TPE materials are mainly used in the manufacturing of high-quality, flexible cables since they can withstand mechanical loads very well and have a high resistance to external influences, such as chemicals or temperatures. TPE can withstand temperatures ranging from -35° C to +100° C, and is also halogen-free. With the addition of flame-retardants, TPE can also be classified as a flame-retardant material, making it UL-compliant. TPE-jacketed cables are the most abrasion-resistant and are often installed inside of cable carriers, especially those that face harsh environmental conditions or fast movements, such as outdoor cranes, conveyor systems, and applications in low temperatures.
Frequently Asked Questions
PVC is a versatile and cost-effective material, but it's not ideal for extreme temperatures and releases toxic halogen gases if it burns. PUR is known for its superior abrasion, tear, and oil resistance, as well as its flexibility in low temperatures. TPE is highly flexible and durable, with excellent resistance to UV, ozone, and a wide temperature range, making it a good choice for dynamic and outdoor applications.
Generally, TPE and PUR offer the best abrasion resistance. TPE-jacketed cables are highly abrasion-resistant and are often used in applications with fast movements, such as on outdoor cranes and conveyor systems. PUR also offers excellent abrasion and notch resistance, making it suitable for use in machine tools and other industrial machinery.
You should choose a PUR jacket if your application requires superior oil, coolant, and abrasion resistance. PUR also has better chemical compatibility than other materials. A TPE jacket is a better choice when you need a highly flexible cable that can withstand a wide range of temperatures, from very cold to very hot. TPE is also a good choice for outdoor applications because of its resistance to UV rays and ozone.
The main disadvantages of a PVC cable jacket are its performance limitations in extreme temperatures and its environmental impact. PVC can become brittle in cold temperatures and soften in very high temperatures. Additionally, when burned, it releases toxic halogen gases, which can be dangerous to humans and the environment.
Both PUR and TPE are excellent for high-flexing applications. PUR is known for its high tensile strength, tear resistance, and ability to be bent repeatedly, making it a top choice for robotics and automation. TPE is also a highly flexible and durable material that is well-suited for dynamic applications with frequent movement.
In the low-voltage range, PVC is considered the most cost-effective material, offering the best price-to-performance ratio for general-purpose use. While it may not have the same specialized resistances as PUR or TPE, its affordability and versatility make it a popular choice for many standard applications.
Yes, both PUR and TPE cables are generally more expensive than PVC cables. While they offer superior performance in specific areas like flexibility, temperature resistance, and durability, this comes at a higher cost.
TPE is a superior choice for applications that are exposed to sunlight and UV rays. It is highly resistant to aging from UV exposure and ozone, making it ideal for outdoor use. PUR also has good UV resistance, but TPE is often cited as being better in this regard.
