TECHNICAL ARTICLE

CABLE INSULATION
WHAT IS CABLE INSULATION?
Insulation is an important non-conductive material that Fluoropolymers: A type of thermoplastic material which will
surrounds and protects the individual wires or cables. Some soften, flow, or distort when subjected to adequate heat and
wire insulation is produced to resist electric current in pressure. These compounds are heated and extruded over the
electrical applications. Other types of insulation are used in conductor. Similarly, the insulation on the finished product
dielectric applications for radio frequency cables. can be re-melted or softened, almost indefinitely, if exposed
to heat. Some of the most common types of thermoplastic
Insulation resists electrical leakage, which prevents the wire’s are polypropylene (PP), polyethylene (PE), polyvinylchloride
current from encountering other nearby wires and cables. It (PVC) , polystyrene (PS), polyethylene theraphthalate (PET)
also preserves the material integrity of the wire by protecting and polycarbonate (PC). There are numerous types of
against environmental threats such as water and heat. The Fluoropolymers that are used for wire insulation.
longevity and effectiveness of a wire depend on its insulation.
The following information shows the different types of wire
Insulation resistance can be measured with a megohmmeter/ insulations that are used in the aerospace industry.
insulation tester without damaging the insulation, and data
so obtained serves as a useful guide in determining the Fluorinated Ethylene Propylene (FEP) is a material type that
general condition of the insulation. Data obtained in this is a highly flame-resistant and commonly used in military
manner, however, may not give a true picture of the condition applications. FEP is also used for foamed wire insulation
of the insulation. Clean, dry insulation having cracks or other for cables since FEP has a low melt temperature, low
faults might show a high value of insulation resistance but dielectric constant (good electrical properties) and high temp
would not be suitable for use. rating overall of +200°C. When foamed, it improves data
transmission and is therefore widely used for cable jackets,
Dielectric strength is the ability of the insulator to withstand especially for coax, like PIC’s “S” cables.
potential difference and is usually expressed in terms of
the voltage at which the insulation fails because of the E10224 is a good example for a data cable that uses a
electrostatic stress. Maximum dielectric strength values can foamed dielectric, or insulation. A dual insulation can also
be measured by raising the voltage of a test sample until the be used, which is a solid inner insulation and foamed outer
insulation breaks down. insulation. This design is used to get the inner wire OD down
to a size to where a standard removal tool can be used to
POPULAR TYPES OF INSULATION remove the wire’s contact from a connector, such as a D-Sub
connector. Refer to T12243 for an example.
There are many varieties of wire and cable insulation just
like there are many types of wires and cables. The type Perfluoroalkoxy (PFA); with a temperature ratings range of
of conductor insulation material varies with the type of -65°C to 250°C, PFA is suitable for high and low temperature
installation. Characteristics should be chosen based on applications. It has superior mechanical strength and its very
environment, abrasion resistance, arc resistance, corrosion low dissipation factor makes it an electrically efficient option.
resistance, cut-through strength, dielectric strength, flame PFA is a more expensive material than FEP. This insulation
resistant, mechanical strength, smoke emission, fluid is used in all of PIC’s data cables that have a PTFE Tape
resistance, and heat distortion. Depending on the application, jacket. The higher temp rating is required because the PTFE
insulation is generally produced from plastic, fluoropolymers tape jacketed cable is run through an oven to cure the jacket
or rubber materials. In the aerospace industry, fluoropolymers and bond it to itself. A foamed PFA insulation would not work
are typically used. either as the added (injected) air in the PFA would heat up too
much, causing a failure in the insulation (melting).

www.PICwire.com | 800.742.3191 | [email protected]

PIC Wire & Cable and PICMates are trademarks of The Angelus Corporation. ©2022 The Angelus Corporation, All rights reserved.
R110122
ISO 9001 • AS 9100 • FAA PMA Certified
CABLE INSULATION
Ethylene Tetrafluoroethylene Copolymer (ETFE) materials Like a foamed FEP, a cable using an ePTFE dielectric can have
offer more strength and flexibility than PFA or FEP and, when the VOP range anywhere from 76% to 82% or higher. The
irradiated, can become thermoset. Foaming the material higher the VOP however, the softer the material, which can
reduces weight and improves data transmission. However, lead to issues when bending a cable which might compromise
the materials lack the electrical advantages offered by FEP. the integrity of the insulation. Also, the softer the material,
ETFE is widely used in lead or hook-up wire for its abrasion the better chance the material can migrate on the wire during
resistance and therefore also widely used as an overall cable the termination process into a connector or when bending or
jacket, as in some of PIC’s coax and data cables. It would routing the cable through an aircraft.
not be used for any dielectric that requires high electrical
performance cables such as Ethernet cables for instance. The SUMMARY
temp rating is +150°C on standard ETFE.
There are many different types of insulation. Each has its
Polytetrafluoroethylene (PTFE) is an extremely flexible, own functions, as well as some similar characteristics. We’ve
and water, oil, chemical, and heat resistant thermoplastic outlined a few in this piece, and by no means is this an
material. Its applications service a wide temperature range of exhaustive list. When choosing the right type of insulation
-60°C to 200°C. PTFE has excellent electrical properties but for an application, it is important to consider how long you
can limit the lengths of cable runs due to the high melting need the cable to last, what the environment will be like, and
point of the material and possibility of cracking after it’s how much protection your cable will need. It can affect the
processed. A large portion of mil spec coaxial cables have longevity of the cables and assure the safety of the cables in
a solid PTFE dielectric, but the super long lengths are not the installation.
required as would be the case with manufacturing single
wires, such as lead or hook-up wires. PTFE tapes are used on At PIC Wire & Cable, we take pride in guiding our clients
cables such as E50824. The tape not only serves as a binder, through the selection process step-by-step. Our experts
but also changes the Impedance of the pairs, thus allowing a understand what will work best for your specific interconnect
reduction in their size (OD). project and can give you options tailored to your needs. From
choosing the right cable for your needs to solving problems or
Expanded Polytetrafluoroethylene (ePTFE) – ePTFE is an concerns about other aspects of your interconnect application,
expanded PTFE. The material has air injected into it during let us handle it!
the extrusion process, similar to foaming. The amount of
air injected into the material depends on the desired VOP
target. The ePTFE material is used for its excellent electrical
properties and its high temperature rating of +260° C.

Figure 1: E6A5826 10G BASE-T CATEGORY 6a 4 PAIR (8-CONDUCTOR) ETHERNET CABLE INSULATION SHOWN

1. PTFE Tape Jacket - White (Laser Markable)

2. Silver-Plated Copper Braided Shield
3. Foil Shields
4.
4. Foamed Fluoropolymer Insulation 3.
2.
1.

www.PICwire.com | 800.742.3191 | [email protected]

PIC Wire & Cable and PICMates are trademarks of The Angelus Corporation. ©2022 The Angelus Corporation, All rights reserved.
R110122
ISO 9001 • AS 9100 • FAA PMA Certified