Which cable jacket is best for your application?

Which Cable Jacket is Best for Your Application?

When selecting the ideal cable jacket for your application, it is essential to consider the characteristics of each material. The primary cable jacket materials include PVC (Polyvinyl Chloride), PUR (Polyurethane), and TPE (Thermoplastic Elastomer). Choosing the right type can greatly extend the longevity and performance of your cables. Here we explore the advantages and limitations of these materials to help you make an informed decision.

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Understanding PVC Cable Jackets

PVC is the most commonly used cable jacket material. It is widely available and cost-effective, making it a popular choice for many applications. PVC offers excellent moisture resistance, which is particularly beneficial in wash-down scenarios. However, it is less suitable for applications requiring high flexibility or resistance to abrasion.

The Benefits of PUR Cable Jackets

PUR cable jackets are more commonly used in Asia and Europe. This material is valued for its resistance to abrasion, oils, and ozone. Additionally, PUR does not contain halogens like chlorine, iodine, fluorine, bromine, or astatine, making it a safer choice in terms of halogen-free requirements. However, it has a narrower temperature range of -40°C to 80°C, compared to other materials.

Advantages of TPE Cable Jackets

TPE jackets are known for their flexibility and recyclability. These cables perform well in extreme cold, with an operating temperature range of -50°C to 125°C. TPE is highly resistant to UV light, ozone, and aging, making it a durable option for outdoor use. It also boasts a high-flex rating, typically around 10 million flex cycles.

Choosing the Right Cable Jacket for Your Needs

The table below provides a comparative analysis of resistance features among the different cable jacket materials. Although these ratings are based on average performance, special compounding can enhance the characteristics of each jacket type.

Key Considerations in Cable Jacket Selection

Choosing the most suitable cable jacket can help minimize failures in the field, ultimately reducing downtime and costs. For extensive options in sensor cables made from PVC, PUR, and TPE, visit Balluff.

Mechanical Durability

The durability of a cable assembly depends on its size and protective layers. The gauge, or thickness, affects its strength. Smaller designs are more prone to damage but offer better flexibility. Protective measures such as proper jacketing, insulation, and armoring can enhance mechanical durability.

Electrical Performance

Two main factors influence a cable's electrical performance: length and shielding. Thicker cables handle higher electrical loads over longer distances. Shielding minimizes electromagnetic interference (EMI), preserving the cable’s current-carrying ability and ensuring reliable signal transmission.

Flexibility Requirements

The flexibility needed depends on the cable's intended use. Flexible cables are ideal for applications with constant movement, like robotic arms. Conversely, rigid cables perform best in stationary, high-power setups. Choosing the right flexibility can prevent snapping and make installation easier.

Temperature and Flame Resistance

Different cables perform uniquely under heat, flame, and cold. Heat-resistant materials include silicone and fiberglass, while flame-resistant options include thermoset materials and FEP. Cold-resistant cables are essential in freezing environments where brittleness could be an issue.

Corrosion Resistance

Industrial environments expose cables to moisture, chemicals, oil, and UV light, all of which can lead to corrosion. Suitable materials include TPU for moisture resistance, FEP for chemical resistance, and TPE for UV protection. Consistently choosing the right materials ensures longevity and reliability.

Processability

Efficiency in production and installation is critical. Materials like EPR, silicone, and polyurethane are easier to strip and process. Automation and ease of termination should be considered to save time and enhance productivity.

Price and Availability

While price is an important factor, it should not overshadow the specific needs of the application. High-performance materials may cost more but offer long-term benefits in demanding environments. Ensure your chosen materials are readily available to avoid unnecessary delays and costs.

For further guidance on selecting cable jackets, explore additional resources and expert opinions to make the best choice for your specific needs. Our dedicated team at FSW is always here to assist with your cable requirements.