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Technical data 2 – Technology for sheathing and screening electrical wire
Materials for sheathing electrical wire
Insulation
– Work for preventing electricity or heat from being conducted. The nonconductor that is used for insulation is called insulator or insulating material.
– Has power supply and load. When they are connected using electric cable, electric current must flow only through power supply → electric cable → load. Therefore, spaces between conductors must be filled with materials where electricity does not flow – insulating materials.
– If there is leaking electric current due to poor insulation, electricity cannot be sent efficiently to load. Various accidents such as fire might occur due to leaking electric current.
– Materials used: Silicone rubber, Teflon, PVC (polyvinyl chloride resin), PE (polyethylene), PP (polypropylene), PA (nylon), PET, etc.
Sheath or jacket
– Refers to external covering for protecting cable core from external environment while producing, constructing, or using the cable
– Materials used: PVC, PE, Teflon, silicone rubber, PUT (polyurethane), etc.
Sheathing materials for cable
Insulation and sheathing materials
| Silicone rubber, SR |
Elastic solid which has slight liquidity in room temperature. Has good heat-resistance and cold-resistance. Has excellent electrical insulation, being used often for special uses such as products that require heat-resistance or heater cableHeat-resistance temperature: 200℃ |
|---|---|
| Teflon, fluorine resin |
Resin which contains fluorine. Has excellent heat and chemical properties, being used often for heat-resistant electric cable There are various types of fluorine resin according to characteristics (FEP, PFA, ETFE, etc.). Since heat-resistance temperature and physical characteristics vary by material types, materials that fit the purpose of use should be selected. Heat-resistance temperature: FEP (200℃), PFA (250℃) ETFE (150℃), PVDF (105℃), PTFE (250℃) |
| PVC (Polyvinyl-Chloride) |
Material that is used most often as general insulation cable and automotive cable. Used by mixing various additives and reinforcing required physical characteristics according to purpose of use Heat-resistant temperature generally has 4 types – 60/75/90/105℃. For heating cable, PVC with heat-resistance temperature of 105℃ is used. Heat-resistance and physical characteristics can be enhanced using Cross-linking (XL) |
| PE (Polyethylene) |
Has excellent non-toxicity, water-proofing, chemical resistance, and insulation resistance Used widely for insulation of cables for communications, electricity, and devices, as well as sheathing materials 3 types according to density: LDPE (low-density), MDPE (middle-density), HDPE (high-density) Heat-resistance temperature: PE 75℃, XLPE 105/125/150℃ Heat-resistance and physical characteristics can be enhanced through Cross-linking (XL) |
| Polyurethane , PUT |
Excellent mechanical strength, tearing strength, abrasion resistance, abrasion resistance, and fine durability are excellent. High durability resistant (2 to 5 times), high elasticity and flexibility for high elasticity and flexibility. Heat temperature : 80 ℃ |
| PET | It is used widely for the base film and the film (carbon) for the heating film. Strong, rigid material with chemical resistance, low moisture content, low heat resistance, and excellent abrasion resistance. |
Classification of resin
| Thermoplastic resin | Resin where its shapes can be changed by applying heat again even after forming it by applying heat. Can be processed efficiently through extruding or injection molding * PE, PVC, PP, PA, PET, TPU, teflon, etc. |
|---|---|
| Teflon, fluorine resin |
Resin that is stiffened when heating. It is molded using the characteristics that is not melted. Cross-linking thermoplastic resin or elastomer produces thermosetting resin. * Silicone rubber, XLPE, XL-PVC, XL-Pipe |
| PVC (Polyvinyl-Chloride) |
Resin that stretches in length by several times when pulled with external force, and comes back to original length when external force is removed * Natural rubber * Silicone rubber, fluorine rubber, neoprene, nitrile rubber, SBR (styrene-butadiene rubber), etc. |
Shield
Shield
Refers to blocking the effects of electric field, magnetic field,
light, heat, etc. from the outside, or blocking leakage to outside
Shielding method
| Braided shield | Spiral/served shield | Tape shield |
|---|---|---|
| It is a method to construct a shielding structure by crossing a copper wire on a core wire, and it is most used among shielding methods because it has appropriate flexibility and mechanical strength. | It is a method to make a shielding structure by winding copper wire on the core wire in the same direction. It is more flexible than braided shielding, but has less structural safety than braiding. | It is a method to Makes a shield structure by coiling metal tape, such as aluminum or copper, over core wire. Facilitates terminal processing but lacks flexibility and has poor curve-resistance |
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Characteristics by shield type
| Classification | Structure (example) | Characteristics |
|---|---|---|
| Copper braiding |  |
– Shield structure where cable core is surrounded with copper wire in net shape – Strong for certain amount of flexibility (becomes hard with large shielding rate) and curving. Mainly used for sites that require mechanical strength – Expensive in general and requires much work during terminal processing – Reduced shield effect with higher frequency, therefore being most effective in low-frequency |
| Copper tape |  |
– Shield structure by coiling tape on cable core – Since access of the shielding layer is easier than AI, appropriate for wiring with many points of curvature that require flexible cable |
| Al-Mylar Tape |  |
– Simple structure that coils AL-Mylar tape on cable core, and inserts drain wire for grounding – Appropriate for lightening cable and has good shielding effect, but has poor flexibility or repetitive flexibility in terms of the entire cable – Inexpensive and is easy to produce, but has poor shielding effect in low frequency *Al Mylar Tape (Polyester tape attached with aluminum foil) |
| Al-Mylar Tape + Copper strand |
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– Double shielding structure which coils Al-Mylar tape on cable core and conducts copper braiding on top of it – Has poor flexibility, but has the best shielding effect among the three structures – Since tape has good high-frequency characteristics and braiding has good low-frequency characteristics, can be used at the widest range |