8 Common Plastics Used in Cables

Plastics are essential in cable manufacturing due to their excellent insulation properties, flexibility, and durability. Understanding the various plastics used in cables will help you choose the right material for your cable needs.

Cables are made with different types of plastics to ensure that they meet specific requirements. From electrical insulation to durability in harsh environments, each plastic offers distinct advantages.

The following sections will explore eight common plastics used in cables. These materials provide key benefits depending on the specific needs of the cable application. Understanding these plastics will help you make an informed choice for your next cable project.

What is PVC and How is it Made?

Polyvinyl chloride (PVC) is one of the most commonly used plastics in cable manufacturing. PVC is a synthetic polymer made from the polymerization of vinyl chloride monomer. It is created by combining the monomer with specific chemicals to form a resin that can be processed into various shapes and forms.

PVC is highly versatile, and it can be produced in both rigid and flexible forms. The rigid form is primarily used in the insulation of cables, while flexible PVC is often used in sheathing applications. PVC’s excellent electrical insulation properties, as well as its chemical and weather resistance, make it an ideal material for a wide range of cable applications.

Types of PVC Used in Cables

Type	Description	Application
Rigid PVC	Hard, durable, and used for insulation	Power cables, industrial cables
Flexible PVC	Soft and bendable, ideal for sheathing	Household, office, and communication cables

Thermoplastic Elastomers (TPE)

Thermoplastic elastomers (TPE) are a group of polymers that combine the properties of rubber and plastic. They offer the flexibility and resilience of rubber while being easier to process like plastic. TPE is widely used in cable manufacturing for applications that require both flexibility and durability.

TPE is commonly used in the insulation and sheathing of cables, especially in applications where the cable is exposed to frequent movement, vibrations, or bending. TPE’s resistance to weather, UV light, and chemicals makes it a great choice for outdoor and industrial applications.

Benefits of TPE in Cables

Property	Description	Benefit
Flexibility	Maintains flexibility even in extreme temperatures	Ideal for cables requiring frequent bending or movement
Durability	Resistant to UV light and chemicals	Perfect for outdoor and industrial applications

Thermoplastic Vulcanizate (TPV)

Thermoplastic vulcanizate (TPV) is a type of thermoplastic elastomer that combines vulcanized rubber with a thermoplastic material. TPV has rubber-like properties, such as elasticity and flexibility, while also maintaining the processability of thermoplastics. This material is used in cable construction where flexibility and durability are crucial.

TPV is especially useful in high-performance applications where exposure to extreme temperatures, weather, and chemicals is common. It is commonly used in automotive cables, industrial cables, and other high-demand applications.

Advantages of TPV in Cables

Property	Description	Benefit
Elasticity	Excellent flexibility and stretchability	Ideal for cables that undergo frequent movement
High-Temperature Resistance	Maintains performance in extreme temperatures	Suitable for automotive and industrial cables

Thermoplastic Polyurethane (TPU)

Thermoplastic polyurethane (TPU) is a highly versatile material known for its exceptional abrasion resistance, high elasticity, and durability. TPU is often used in cable sheathing where mechanical strength and flexibility are needed. It is resistant to oils, greases, and various chemicals, making it suitable for industrial and outdoor applications.

TPU’s ability to retain its flexibility at low temperatures and its high tensile strength make it a preferred choice for cables that need to withstand harsh conditions.

Key Advantages of TPU in Cables

Property	Description	Benefit
Abrasion Resistance	Offers high resistance to wear and mechanical damage	Ideal for cables exposed to frequent friction and wear
Chemical Resistance	Resistant to oils, greases, and solvents	Perfect for cables used in industrial environments

Copolyester Elastomer (TPC)

Copolyester elastomer (TPC) is a material that combines the properties of polyester and elastomeric compounds. This material is designed to offer a balance of strength, flexibility, and resistance to environmental conditions. TPC is used in the manufacturing of cables where a combination of flexibility and durability is required.

TPC’s high resistance to oils, chemicals, and high temperatures makes it a popular choice for use in the automotive and industrial sectors.

Benefits of TPC in Cable Applications

Property	Description	Benefit
Strength	Offers strong resistance to physical stresses	Suitable for heavy-duty cables in industrial applications
Chemical Resistance	Protects against chemical exposure	Ideal for cables used in harsh environments

Polypropylene (PP)

Polypropylene (PP) is a thermoplastic polymer known for its lightweight nature, excellent chemical resistance, and high melting point. PP is commonly used in cable insulation and sheathing, especially when low weight is a primary consideration. It provides an excellent barrier to moisture and is resistant to most chemicals.

Key Features of Polypropylene in Cables

Property	Description	Benefit
Lightweight	Reduces the overall weight of cables	Ideal for applications where weight is a concern
Moisture Resistance	Protects against water and moisture damage	Ensures longevity in damp environments

Polyethylene (PE)

Polyethylene (PE) is one of the most widely used materials in the cable industry due to its outstanding electrical properties, low cost, and easy processability. PE is commonly used in insulation and sheathing applications, especially in power cables, where high dielectric strength is required.

PE’s resistance to moisture, chemicals, and UV light makes it a suitable material for outdoor and underground cable installations.

Benefits of Polyethylene in Cable Applications

Property	Description	Benefit
Electrical Insulation	Excellent electrical insulating properties	Ideal for use in high-voltage cables
Chemical Resistance	Resistant to environmental stressors	Perfect for outdoor and underground cables

Ethylene Vinyl Acetate (EVA)

Ethylene vinyl acetate (EVA) is a flexible, durable material used in the cable industry. It is often employed in the insulation and sheathing of cables, particularly those used in harsh environments. EVA offers a good balance of flexibility, durability, and low-temperature performance.

EVA’s superior impact resistance and low moisture absorption make it ideal for cables that are exposed to physical stress or moisture, especially in outdoor environments.

Advantages of EVA in Cables

Property	Description	Benefit
Flexibility	Maintains flexibility across a range of temperatures	Ideal for use in low-temperature applications
Impact Resistance	Offers protection against physical impact	Ensures durability in harsh environments

Conclusion

The selection of plastics in cable manufacturing depends on the specific needs of the application. From flexibility to chemical resistance, each material offers distinct advantages. Understanding the unique