When we think about electrical cables, most people focus only on the conductor material—copper or aluminum. But the conductor is only part of the story. Equally important is the jacket (or insulation material), which determines how well the cable survives in different environments. Just like people wear different clothes for winter, summer, or extreme sports, cables need their "jackets" to match their working conditions.
So why do we see so many choices—PVC, XLPE, rubber, silicone, and more? Let’s dive deeper.
Electrical cables face highly diverse conditions. A cable inside a residential building may only need to handle mild temperatures, while one used in a steel plant faces constant exposure to 90°C+ heat. A mining cable may endure heavy mechanical stress, bending, water, and oil.
The insulation material determines whether the cable performs safely or fails prematurely. Some key performance factors include:
Thermal resistance: Can it withstand high operating temperatures without melting?
Mechanical flexibility: Does it need to bend repeatedly, or stay fixed?
Chemical resistance: Can it handle oil, acid, UV exposure, or solvents?
Moisture protection: Will it be buried underground, underwater, or exposed outdoors?
Flame retardancy: Will it spread fire, or self-extinguish?
Clearly, one material cannot satisfy all these requirements. That’s why manufacturers provide a range of insulation types.
PVC is by far the most widely used insulation. Its popularity comes from low cost and easy processing.
Advantages:
Affordable and widely available.
Flexible enough for simple installation.
Decent resistance to mild chemicals and moisture.
Flame-retardant grades available.
Limitations:
Maximum operating temperature: ~70°C (short-circuit ~160°C).
Poor resistance to sunlight and UV—outdoor use leads to brittleness.
Mechanical durability is limited; cracks can appear over time.
Typical Applications:
Domestic house wiring.
Low-voltage power distribution.
Appliances and consumer electronics.
