5 Common Types of Wire Insulation for Wiring Harnesses Manufacturing


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Our custom cable assemblies have better wiring and insulation than off-the-shelf cable assemblies. You can choose the connector that you want throughout your cables; you can also choose the material of the wiring itself. We test out wires for the best performance that you can buy, ensuring that the custom cable that you are buying is the best around.

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Wiring harnesses an effective 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 cause damage. You get to choose from different materials for wire insulation. The selection of the material depends upon the work environment and layout of the wire harness.

cored wire wrapped in plastic
Copper-cored wire wrapped in plastic

For industrial and commercial projects, CLOOM Tech offers five different types of wire insulations for custom wiring harnesses. 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 applications in electric cable manufacturing as bedding, insulation and sheathing material. PVC was an advance and better alternative to rubber insulated wires as PVC was easy to process than the rubber sheathing. As you are not going to 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 of the 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 rise in temperature.

Wire insulation for different applications
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 chances of chemical exposure.

Examples of PVC Applications

In many wires and cables, you will find PVC as the main 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 type 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 for chemicals make it a suitable option for wire insulation in wiring harnesses.

Insulation of wire in different colours for several applications
Insulation of wire in different colours for several applications

When it comes to temperature resistance, FEP offers great resistance temperature ranges. Due to amazing 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. Due to the excellent temperature and chemical resistance properties, FEP has countless applications in commercial and industrial projects.

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

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 rigid 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
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. From low or high voltage current-carrying wires, you will get a maximum efficient supply of current with Polyethylene insulated wires. What makes Polyethylene a better choice as compared to other insulation materials?

The additional properties of Polyethylene make it a suitable coating material for high frequency signally carrying wires and transmission lines. 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 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 the other, 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, yet the toughness of Nylon can protect the wires against external factors and abuse. At some point where a lot of 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
Macro detail of some cables

Benefits of Nylon for Wire Insulation in Wire Harnesses

Apart from the easy availability of Nylon 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 low cost and effective 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 the least investment. The processing of Thermoplastic Rubber does not require a lot of processing, making it an affordable option for industrial applications.

Electrical tester wires tying cables bolt cutter pliers
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. If we compare Thermoplastic Rubber with other thermoplastic insulation materials, it is the most flexible material out there. 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

No matter what are your project specifications and work environment requirements, CLOOM Tech can manufacture custom harnesses with any insulation material. You can contact us for bulk production of custom wiring harnesses with different protective coatings and insulations.

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