5 Common Types of Wire Insulation for Wiring Harnesses Manufacturing

Wiring harnesses a compelling piece to combine several wires and conductors in order. Without proper wire insulation, the connection of different cables and strands within the wire harness can be damaged. You get to choose from other materials for wire insulation, and the selection of the material depends upon the work environment and layout of the wire harness.

Copper-cored wire wrapped in plastic

CLOOM Tech offers five different types of wire insulations for custom wiring harnesses for industrial and commercial projects. Here is a brief introduction of every wire insulation type the technical specifications of the materials.

1. Polyvinyl Chloride

PVC has a wide range of electric cable manufacturing applications as bedding, insulation, and sheathing material. PVC was an advanced and better alternative to rubber insulated wires as PVC was more accessible to process than rubber sheathing. As you will not replace or repair custom wiring harnesses any sooner; hence, PVC offers an excellent lifespan. The cost of PVC is less than many other wire insulation materials.

PVC is one of the most flexible and versatile thermoplastics due to its fantastic flexibility. The original properties of PVC make it rigid and challenging, but it is useable in different applications after easy modifications. The processing of PVC is easy, and it is also recyclable. During the selection of material for wire insulation, fire resistance is an important consideration. Most industrial applications require such fabric for wire insulation and cable sheathing that can withstand higher temperatures. The use of PVC for wire insulation in wiring harnesses allows the harnesses to perform effectively despite the temperature rise.

Wire insulation for different applications

Apart from high-temperature resistance, PVC insulation can protect wires against oils and chemicals too. The chemical exposure is too regular in many industrial work settings, so you can opt for PVC insulation if there are any chemical exposure chances.

Examples of PVC Applications

In many wires and cables, you will find PVC as the primary insulation material. CLOOM Tech also offers modified PVC insulation for custom wiring harnesses according to the requirements of the client. Here are some significant examples of PVC insulated wires:

• As jacketing and insulation for low voltage wires
• Cable jacketing for medium and low voltage appliances
• For local telecommunication cables
•  In wiring harnesses for automotive.
• Flexible wires for better protection against tearing

2. Fluorinated Ethylene-Propylene

FEP is the blend of hexafluoropropylene and tetrafluoroethylene. FEP materials are modifiable after melting. This material is a perfect insulation material for temperature sensing wires, but its use for wiring harnesses also has some benefits. FEP has countless applications in industrial units as insulation and jacketing material for wires and cables. In coaxial cables, this material can perform as a dielectric too. The outstanding resistive properties of chemicals make it a suitable option for wire insulation in wiring harnesses.

Insulation of wire in different colors for several applications

When it comes to temperature resistance, FEP offers great resistance temperature ranges. Due to its excellent electric and physical properties, manufacturers use FEP in many industries and projects. In TEC cables, manufacturers use FEP as filler material. These TEC cables are perfect for the gas and oil industries. FEP is an excellent option for wiring harnesses for military installations and applications. FEP has countless applications in commercial and industrial projects due to its ideal temperature and chemical resistance properties.

Whenever you need wiring harnesses with flexible yet rigid insulation material, you can choose FEP as protective material. FEP can withstand all weather conditions with effective water resistance properties if you are concerned about changing weather conditions.

Applications of FEP Insulation

Almost every industry has some space for FEP as insulation for custom wiring harnesses. Typical industrial applications of FEP as wire insulation include:

• Military installation and military-grade equipment
• Oil and gas units where chemical exposure is a common problem
• Chemical industries with harsh work settings
• Medical facilitates that need sterilization of wires and wiring harnesses.
• Aviation and aerospace sector
• Cars and vehicle manufacturing units

3. Polyethene

Polyethene insulated wires are best for projects where high voltage is involved. From electrical properties to resistance against different levels of temperature, Polyethylene is suitable for harsh conditions. In various applications where general sheathing materials would fail, manufacturers use Polyethylene as an insulation material. From freezing conditions to boiling applications, Polyethylene can withstand both extremes.

The wiring harnesses with a coating of Polyethylene are rigid but offer better resistance against abrasion. The original chemical properties of Polyethylene make it a tough and solid material. In the original form, Polyethylene may not be suitable for wires where you need flexibility. But with some further modifications of additives and fillers, you can make it flexible according to the project specifications.

Close up of electric cables with insulation

Polyethene insulation is the perfect choice to minimize power loss. The leakage of current or data from wires with Polyethylene coating is almost negligible. You will get a maximum efficient current supply with Polyethylene insulated wires from low or high voltage current-carrying wires. What makes Polyethylene a better choice as compared to other insulation materials?

Polyethylene’s additional properties make it a suitable coating material for high-frequency signally carrying wires and transmission lines. For all the appliances that involve audio data and radio frequencies, custom wiring harnesses with Polyethylene coating can perform better than other typical coating materials.

Different Types of Polyethylene

There are different types of PE, depending upon the chemical properties of the material. Polyethene is originally lightweight, chemically inert, and water-resistant. Here are different types of PE:

• Low-density PE
• Linear low-density PE
• Medium-density PE
• High-density PE
• Chlorinated PE
• Cross linkable PE

4. Nylon

Thermoplastic materials for the insulation of wires in custom wiring harnesses are less expensive as compared to thermosets. There are realities of wires and cables that feature different insulating materials according to the project specifications. Each material has some benefits over others, as some are soft, and some exhibit rigid attributes.

When it comes to soft materials for wires in custom wiring harnesses, manufacturers look forward to PVC or Nylon. Both are highly flexible and adjustable according to the project specifications and harness layout. In some industries like automotive and aerospace industries, Nylon seems to be a perfect choice. Although this material is flexible, Nylon’s toughness can protect the wires against external factors and abuse. When many bending and mechanical movements are involved, custom wiring harnesses with Nylon insulation can perform better. The strain relief and flexibility of Nylon insulation are way better than many other insulation materials.

Macro detail of some cables

Benefits of Nylon for Wire Insulation in Wire Harnesses

Apart from Nylon’s easy availability as insulation material, the price of Nylon is also less than other materials. Many clients prefer to have custom wire harnesses with Nylon insulation due to their low cost and functional properties. The following are some unique advantages of Nylon.

• Nylon is a highly flexible and soft material that is perfect for insulation.
• The rigidness of Nylon makes it tough insulation in the original form.
• It has a string of abrasion resistance properties.
• Nylon provides better protection against tearing and cut through.
• The chemical resistance of Nylon makes it excellent insulation for industrial projects too.

5. Thermoplastic Rubber

Thermoplastic rubber is the primary focus of custom wiring harnesses manufacturers. The fantastic properties of Thermoplastic Rubber make it a better option for the insulation of wires with a minor investment. The processing of Thermoplastic Rubber does not require a lot of processing, making it an affordable industrial application option.

Electrical tester wires tying cables bolt cutter pliers

The use of Thermoplastic Rubber for cable insulation and jacketing is nothing new as this material has been around for a long time. The unique physical properties and low processing costs make it a desirable material for custom wiring harness manufacturers. It is the most flexible material out there if we compare Thermoplastic Rubber with other thermoplastic insulation materials. Even after stretching the material to a sufficient elongation, Thermoplastic Rubber will return to the original shape. Hence, improved flexibility leads to the enhanced lifespan of the wires and cables.

Properties of Thermoplastic Rubber

Here are some unique physical and chemical properties of Thermoplastic Rubber that make it a perfect choice of wire insulation in custom wiring harnesses:

• Higher processing speed leads to faster production.
• Temperature resistance against extreme temperature levels
• Excellent resistance against weather and heat ranges
• Enhanced lifespan with the better ageing process

Conclusion

CLOOM Tech can manufacture custom harnesses with any insulation material regardless of your project specifications and work environment requirements. You can contact us for bulk production of custom wiring harnesses with different protective coatings and insulations.