By Eileen Harvey
In process control, robotics, and automotive systems, bus cables serve as vital connectors that reliably transmit data and power. While the focus often centers on the conductors and shielding, the cable jacket material is equally important. The jacket safeguards the cable against mechanical damage, exposure to chemicals and oils, UV radiation and temperature fluctuations, ensuring durability and safety over time.
The most used jacket materials are PVC (polyvinyl chloride), PUR (polyurethane), and TPE (thermoplastic elastomer). Each material offers distinct advantages and considerations tailored to specific operational environments. Selecting an inappropriate jacket material can result in early cable failure, system downtime and increased maintenance expenses. Making the right choice is essential for ensuring long-lasting performance and system reliability.
Role of Cable Jackets in Bus Applications
A cable jacket is much more than an outer covering. It plays a vital role in protecting conductors from abrasion, cuts, and crushing, while also preventing damage from oils, chemicals, UV exposure and moisture. Cable jackets contribute to thermal stability by maintaining their integrity across a wide range of temperatures. They also influence flexibility and handling, which is especially important in robotics or drag-chain systems where frequent movement is required. In addition, cable jackets support regulatory compliance by meeting fire safety, halogen-free or eco-friendly standards. Without the right jacket material, even the most advanced cable design can fail prematurely.
PVC (Polyvinyl Chloride) Jackets
PVC jackets are affordable and widely available. They are flame-retardant, good electrical insulators, and come in a variety of hardness levels. The advantages of PVC include cost-effectiveness, which makes them ideal for large-scale installations, strong electrical insulation for reliable general-purpose use, and ease of processing that allows for simple routing and connections.
However, PVC jackets have limitations. They provide poor resistance to oils, UV rays and chemicals, making them unsuitable for continuous motion or harsh outdoor environments. Their lifespan is also limited in extreme temperatures. For this reason, PVC jackets are best suited for indoor bus systems, office environments and light industrial setups. An example of this type is the PROFIBUS 150 Ohm PVC Jacket Cable.
PUR (Polyurethane) Jackets
Polyurethane jackets are known for being highly flexible and tough. They resist abrasion, oils, and chemicals and can withstand continuous flexing in drag-chain systems. The main advantages of PUR include superior durability in harsh conditions, excellent flexibility for robotic and moving machinery, and strong chemical resistance suitable for automotive and industrial plants.
The trade-offs include higher cost compared to PVC and sometimes reduced flame resistance unless the material is specially formulated. PUR jackets are best used in robotics and automation, automotive manufacturing lines, and outdoor or heavy-duty environments. A good example is the CAN-Bus PUR Jacket Cable, Stranded 120 Ohm.
TPE (Thermoplastic Elastomer) Jackets
TPE jackets are halogen-free and eco-friendly, offering flexibility across a wide temperature range. They balance chemical, UV and weather resistance while maintaining strong environmental performance. Their advantages include reduced toxic emissions thanks to halogen-free formulations, versatility that allows them to perform well both outdoors and indoors, and low-temperature flexibility that makes them ideal for cold storage or outdoor automation.
On the downside, TPE jackets are more expensive than PVC and may not always offer the same abrasion resistance as PUR. They are best suited for outdoor bus installations, environments requiring halogen-free safety, and harsh or extreme settings where UV and chemical exposure are concerns. An example is the ASI-Bus TPE Oil-Resistant Cable.
Factors to Consider When Choosing a Cable Jacket
When selecting the right jacket material, several factors should be evaluated. First, the environment is key: indoor applications have different needs than outdoor ones, especially when considering exposure to oils, UV rays or chemicals. Mechanical stress is another consideration, as fixed installations place different demands on a cable compared to continuous motion systems. Temperature range must also be evaluated to ensure the cable can operate in freezing or high-heat conditions. Regulatory requirements should be factored in as well, particularly when flame-retardant, halogen-free or eco-friendly standards apply. Finally, budget considerations play a role, requiring a balance between cost and long-term durability.
Tips for Choosing the Right Jacket
- For indoor office/light automation, choose PVC to save costs.
- For robotics, drag chains or moving equipment, go with PUR for flexibility and wear resistance.
- For outdoor or chemical-heavy environments, select TPE for UV, oil and extreme weather resistance.
- Consult with cable experts like TKD Kabel to match cable jackets with your system requirements.
Selecting the appropriate cable jacket material is a critical step in designing and maintaining reliable bus systems across various industries. PVC, PUR and TPE each bring distinct advantages tailored to different environmental, mechanical and regulatory requirements. By evaluating factors such as environmental exposure, mechanical demands, cost and safety standards, professionals can choose the most suitable material to ensure them bus cables perform optimally throughout their service life.
Investing time and expertise in this decision can prevent premature failures, reduce maintenance costs and enhance overall system safety, making it a vital aspect of modern industrial and automotive system design.
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Explore the full range of TKD Kabel through L-com. We’ll fill your orders fast, with same-day shipping on all qualified, in stock, online orders received Monday through Friday before 5 p.m. EST. For TKD-related inquiries, connect with our U.S-based TKD expert Eileen Harvey at eharvey@infiniteelectronics.com.
