Insulations and Jackets
Typical Characteristics of Popular Insulation and Jacketing Compounds
 
 
EPDM
EPDM (ethylene-propylene-diene elastomer)
is a chemically cross-linked elastomer with
excellent flexibility at high and low temperatures
(150° to -55°C). It has good insulation
resistance and dielectric strength, as well as
excellent abrasion resistance and mechanical
properties. EPDM also has better cut-through
resistance than Silicone rubber, which it
replaces in some applications.
EPDM is compatible with most varnishes, but
after the dip and bake cycle varnish tends to
adhere to the insulation (because EPDM,
unlike some rubber insulations, does not
exude oils or waxes). As lead wires are
pulled apart for termination, the varnish
cracks, sometimes breaking the insulation.
To resolve this problem, a stearic solution
is applied to the lead wire during the put-up
process. This ensures that rigid varnish
does not cause EPDM insulation to rupture
when the wire is terminated.
Field evaluations by numerous users reveal
that the coated EPDM has excellent varnish
resistance at least equal to synthetic elastomers,
cross-link polyethylene, or Silicone
glass braid in dip and bake systems.
 
 
 
 
 
 Flamarrest®
Flamarrest is a plenum grade chloridebased
jacketing material with low smoke
and low flame spread properties. Cables
jacketed with Flamarrest meet the ANSI/
NFPA Standard 262-1985 (UL910),
Plenum Cable Flame Test.

Halar®
Thermoplastic fluoropolymer material with
excellent chemical resistance, electrical
properties, thermal characteristics, and
impact resistance. The temperature rating
is -70°C to 150°C.

Neoprene
The temperature range of this material can
vary from -55°C to 90°C. The actual range
would depend on the formulation used.
Neoprene is both oil-resistant and sunlightresistant,
making it ideal for many outdoor
applications. The most stable colors are
Black, Dark Brown, and Gray. The electrical
properties are not as good as other insulation
materials. Because of this, thicker insulation
should be used. Typical designs where this
material is used are lead wire insulation
and cable jackets.
Polyethylene (Solid and Foamed)
A very good insulation in terms of electrical
properties. Low dielectric constant, a stable
dielectric constant over all frequencies,
very high insulation resistance. In terms of
flexibility, polyethylene can be rated stiff to
very hard, depending on molecular weight
and density—low density being the most
flexible, with high-density, high-molecular
weight formulation being very hard. Moisture
resistance is rated excellent. Black and
specially formulated colored versions have
excellent weather resistance. The dielectric
constant is 2.3 for solid insulation and
typically 1.64 for foam designs. Flame
retardant formulations are available with
dielectric constants ranging from about
1.7 for foam flame retardant to 2.58 for
solid flame retardant polyethylene.
 
Polypropylene (Solid and Foam)
Similar in electrical properties to polyethylene.
This material is primarily used as
an insulation material. Typically, it is harder
than polyethylene. This makes it suitable
for thin wall insulations. UL maximum
temperature rating may be 60°C, 80°C or
105°C. The dielectric constant is 2.25 for
solid and typically 1.55 for foam designs.
 
Polyurethane
This material is used primarily as a cable
jacket material. It has excellent oxidation,
oil, and ozone resistance. Some formations
also have good flame resistance. It is a hard
material with excellent abrasion resistance.
It has outstanding “memory” properties,
making it an ideal jacket material for
retractile cords.

PVC
Sometimes referred to as vinyl or polyvinylchloride.
Extremely high or low temperature
properties cannot be found in one
formulation. Certain formulations may have
-55°C to 105°C rating. Other common
vinyls may have -20°C to 60°C. There
are many formulations for the variety of
different applications. The many varieties
of PVC also differ in pliability and electrical
properties. The price range can vary
accordingly. Typical dielectric constant
values can vary from 3.5 to 6.5.

Rubber
The description of rubber normally includes
natural rubber and SBR compounds. Both of
these materials can be used for insulations
and jackets. There are many formulations of
these basic materials. Each formulation is
for a specific application. Some formulations
are suitable for -55°C minimum, while
others are suitable for 75°C maximum.

Silicone
This is a very soft insulation which has a
temperature range from -80°C to 200°C.
It has excellent electrical properties plus
ozone resistance, low moisture absorption,
weather resistance, and radiation resistance.
It typically has low mechanical strength and
poor scuff resistance.
Teflon®
This material has excellent electrical
properties, temperature range and
chemical resistance. It is not suitable
where subjected to nuclear radiation
and does not have good high voltage
characteristics. FEP Teflon is extrudable
in a manner similar to PVC and polyethylene.
This means that long wire
and cable lengths are available. TFE
Teflon is extrudable in a hydraulic ram
type process. Lengths are limited due
to amount of material in the ram, thickness
of the insulation, and preform size. TFE
must be extruded over a silver- or nickelcoated
wire. The nickel- and silver-coated
designs are rated 260°C and 200°C
maximum, respectively. The cost of
Teflon is approximately 8 to 10 times
more per pound than PVC compounds.
 
Tefzel®
Fluorocopolymer thermoplastic material
having excellent electrical properties, heat
resistance, chemical resistance, toughness,
radiation resistance, and flame resistance.
The temperature rating is -65°C to 150°C.
Teflon
 
Rubber
The description of rubber normally includes
natural rubber and SBR compounds. Both of
these materials can be used for insulations
and jackets. There are many formulations of
these basic materials. Each formulation is
for a specific application. Some formulations
are suitable for -55°C minimum, while
others are suitable for 75°C maximum.

Silicone
This is a very soft insulation which has a
temperature range from -80°C to 200°C.
It has excellent electrical properties plus
ozone resistance, low moisture absorption,
weather resistance, and radiation resistance.
It typically has low mechanical strength and
poor scuff resistance.
 
Teflon®
This material has excellent electrical
properties, temperature range and
chemical resistance. It is not suitable
where subjected to nuclear radiation
and does not have good high voltage
characteristics. FEP Teflon is extrudable
in a manner similar to PVC and polyethylene.
This means that long wire
and cable lengths are available. TFE
Teflon is extrudable in a hydraulic ram
type process. Lengths are limited due
to amount of material in the ram, thickness
of the insulation, and preform size. TFE
must be extruded over a silver- or nickelcoated
wire. The nickel- and silver-coated
designs are rated 260°C and 200°C
maximum, respectively. The cost of
Teflon is approximately 8 to 10 times
more per pound than PVC compounds.
 
Tefzel®
Fluorocopolymer thermoplastic material
having excellent electrical properties, heat
resistance, chemical resistance, toughness,
radiation resistance, and flame resistance.
The temperature rating is -65°C to 150°C.