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Cable Design:   Insulation/Jacket
Based on the requirements, the best insulating material for the application will be selected. The selection may involve examination of many different performance properties. The properties are addressed in the following sections and tables.

General Terms:

Thermoplastic: Materials that soften and flow when heated. Usually possess a definite melting point. The material will become firm again upon cooling. These materials can be molded and shaped with a heating and cooling process. (This process can be repeated.) Extrusion of melt flow polymers on wire is an example of this type of material.

Thermoset: Materials are soft and pliable during one stage of processing, can be molded and extruded at this state after which they are set or cured, usually at a higher temperature. After the setting process (cross linking) is complete they cannot be softened by reheating, hence heat and solvent resistance properties are improved over thermoplastic materials.

Insulation: Materials possessing good dielectric properties used on wire components in cable usually as direct covering on conductors.

Jacket: Materials that provide a protection in mechanical and chemical properties applied as a direct covering over cable components. The choice of materials for cable design to satisfy any given combination of installation and environmental conditions can often be more critical than the electrical requirements.

 

Insulation and Jacket Compound Properties (Nominal Values)

Material

Max Operating
Temp C

Dielectric
K @ 1Mhz

Specific
Gravity

Ozygen
Index

Vinyl (PVC)

Plasticized (Conventional)

105

4.6

1.38

26-30

Semi Rigid

80

4.0

1.39

36

Irradiated

105

2.70

1.38

27

Polyethylene

Low Density

80

2.28

0.92

18

High Density

80

2.34

0.95

18

Flame Retardant

80

2.35

1.0

27

Cellular (Foam)

80

1.55*

0.50*

18

Cross-Linked

90

2.44

1.19

27

Polypropylene

Solid

90

2.30

0.91

18

Cellular (Foam)

90

1.50*

0.50*

18

Thermoplastic Elastomer

105

2.80

1.20

32

Teflon FEP

Solid

200

2.1

2.15

95

Cellular (Foam)

200

1.4*

1.1*

40

Teflon PFA

250

2.1

2.15

30

Tefzel (ETFE)

150

2.6

1.7

30

Kynar (PVDF)

135

6.4

1.76

44

Haalr (ECTFE)

150

2.56

1.7

30

Nylon

105

4-8

1.13

22

Mylar (Polyester)

150

3.0

1.40

20

Polurethane

80

-

1.13

20-29

Solef (PVDF)

150

-

1.78

40

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