By Eileen Harvey
When it comes to selecting the right cable for industrial, automation or everyday applications, the cable jacket material plays a crucial role. A cable’s jacket not only protects the internal conductors but also determines the cable’s durability, flexibility, chemical resistance and overall performance in different environments.
On the other hand, PUR is celebrated for its exceptional flexibility, abrasion resistance and resilience in harsh environments, positioning it as a premium option for demanding applications. TPE, a newer contender, combines the best properties of rubber and plastic, offering excellent elasticity and adaptability, which is particularly beneficial in dynamic applications
But how do you know which one is best for your needs? Let’s break it down by exploring the properties, advantages and applications of each.
Overview of Cable Jacket Materials
Cable jackets serve as the first line of defense against external stress factors such as moisture, oil, abrasion, UV exposure and mechanical wear. The choice of jacket material can make the difference between a cable lasting a few months or several years in a demanding environment.
The three most popular materials in industrial and control cable design are PVC, PUR and TPE. PVC (polyvinyl chloride) is affordable and versatile, widely used for general applications. PUR (polyurethane) is highly flexible and resistant to abrasion, ideal for robotic and motion control cables. TPE (thermoplastic elastomer) is eco-friendly, chemical-resistant and suitable for harsh environments.
Properties of PVC Cable Jackets
PVC is one of the most commonly used materials in cable jackets. It’s popular due to its low cost, ease of processing and wide availability. It has four main advantages. First, it is cost-effective. It’s affordable compared to PUR and TPE, making it ideal for general-purpose cables. Second, PVC has good insulation properties, providing reliable electrical insulation. Its third advantage is that it has moderate flexibility, suitable for static and light-flexing applications. Fourth, it has chemical resistance against oils, acids and alkalis to some extent.
Applications:
PVC jackets are commonly used in data cables, control cables and household wiring, where flexibility is not a primary concern. For example, industrial Ethernet cables often use PVC for indoor installations.
Limitations:
PVC has three notable limitations. First, it is not highly resistant to abrasion. Second, it has limited performance in extreme temperatures (-10°C to +70°C typically). And third, it can release toxic fumes when burned, making it less suitable for certain safety-sensitive environments.
Overall, PVC is best for cost-sensitive, standard environments where cables are not subject to continuous flexing or mechanical stress.
Advantages of PUR Cable Jackets
PUR (polyurethane) stands out for its mechanical toughness and flexibility. This makes it particularly suitable for dynamic applications such as robotics, conveyor systems and drag chain installations. It has four main advantages.
First, it has superior abrasion resistance, ideal for environments where cables are dragged or moved frequently. Second it has high flexibility, perfect for continuous motion and tight bending radii. Its third advantage is its oil and chemical resistance, performing well in industrial settings with oils, greases and solvents. Fourth, it is tear-resistant, offering enhanced durability in demanding conditions.
Applications:
PUR jackets are widely used in robotics, automation and machine tools. For example, robotic cables and control cables in manufacturing plants often feature PUR jackets for an extended lifespan. L-com’s industrial-grade cables are designed for demanding motion control environments.
Limitations:
PUR’s three main limitations are that is more expensive than PVC, it is sensitive to hydrolysis in very humid conditions unless specially treated and it can be stiffer compared to TPE in very low temperatures.
Overall, PUR is the best choice for demanding industrial and robotic applications where flexibility and resistance to mechanical stress are critical.
Benefits of TPE Cable Jackets
TPE (thermoplastic elastomer) combines the advantages of plastics and rubber, making it a versatile and environmentally friendly option. It has been gaining popularity in modern cable design. It has five big advantages.
First is its wide temperature range, performing in both hot and cold environments (-50°C to +125°C depending on the blend). Second is the fact that it is eco-friendly. It is halogen-free and recyclable, making it a greener choice than PVC. TPE’s third advantage is its excellent flexibility, maintaining performance in both static and dynamic applications. Fourth is its resistance to chemicals and UV, making it suitable for outdoor and industrial use. The fifth benefit is TPE’s low smoke emission, making it safer in fire situations compared to PVC.
Applications:
TPE jackets are used in medical devices, renewable energy, outdoor equipment and automation systems where environmental safety and flexibility are important.
Limitations:
TPE’s two main limitations are that it is higher cost compared to PVC, and it can be less abrasion-resistant than PUR.
Overall, TPE strikes a balance between environmental responsibility, flexibility and durability, making it a strong contender for next-generation cable solutions.
Choosing the Right Material
When deciding between PVC, PUR and TPE, consider four factors.
First is application environment. PVC is best indoors and under low stress. PUR is good for high-motion, robotic and abrasive environments. TPE excels outdoors and is eco-friendly and chemical resistant.
The second factor is flexibility needs. PVC is best for static wiring while PUR and TPE suit continuous movement.
The third factor is budget considerations. PVC suits cost-sensitive projects. PUR and TPE are best for long-term reliability and performance.
Factor 4 is safety and compliance. TPE is best when there are fire safety and halogen-free requirements.
Tips for Selecting the Right Cable Jacket
- Always check the manufacturer’s datasheet for temperature, chemical resistance and flexibility ratings.
- Match cable material to motion type: If your system involves constant bending or drag chains, avoid PVC.
- Plan for the environment: Outdoor applications need UV and weather-resistant materials like PUR or TPE.
- Think long-term: While PUR and TPE cost more, they often reduce replacement and downtime costs.
- Consult experts: Distributors likeL-com provide detailed specifications for different cable types.
Selecting the right cable jacket material is just as important as choosing the conductor or insulation. PVC, PUR and TPE each serve different needs, from cost-effective solutions to high-performance, eco-friendly options. By carefully assessing your application environment, flexibility needs and safety requirements, you can choose the jacket material that ensures long-lasting performance and reliability.
