Why is FR Polyethylene Cable Compounds Custom Better?

10 Most Common Types of Cable Filler Material

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When constructing a custom cable assembly, manufacturers frequently include filler material to separate distinct sections and/or to fill the spaces between conductors or wires. Fillers play multiple roles within a cable, from providing additional protection against environmental factors to extending the cable's lifespan.

While cable filler occupies extra space around the conductors, its primary function is to help form the cable shape, which is typically circular. If there are fewer wires, the shape is usually maintained and/or the wires do not experience excessive movement, extreme temperatures, or harsh conditions, the filler may not be necessary.

For those that require it, several types of filler materials are available, each with unique properties and advantages. Knowing your options can greatly enhance your assembly's performance and durability for its intended application.

What Do Cable Fillers Add to a Cable Assembly?

Fillers, depending on their material, can enhance a cable's effectiveness, longevity, and appearance by helping:

• Maintain cord shape. Proper shape retention aids performance and durability while preserving the intended look and structural specifications.

• Enhance strength. Fillers improve tensile strength, flexibility, and flex life, which reduces the likelihood of splitting and premature wear.

• Protect against elements. Liquids such as water and chemicals are significant hazards that cable assemblies must avoid. Fillers help maintain the dryness of internal wires.

• Reduce friction. Increased friction raises the risk of electric shock. Fillers securely hold wires in place without them rubbing against each other, enhancing safety.

• Shield against extreme heat. Electrical systems can generate high temperatures, leading to safety concerns and accelerated degradation if not appropriately managed. Fillers provide protection against heat damage.

• Minimize interference. Certain fillers offer electromagnetic shielding, reducing electrical noise that can impact conductor performance.

For superior cable assembly and wire harness manufacturing solutions, trust the experienced team at CAI to choose just the right cable fillers, conductors, insulation, and more for your electrical or mechanical application.

10 Popular Types of Cable Filler Material

Cable fillers generally fall into two primary categories: high-temperature (HT), which can endure extreme heat, and low-temperature (LT), suitable for the majority of cable applications in moderate conditions. Here are 10 common filler options applicable across various uses:

Polyimide Tape:

Known for its mechanical strength and resistance to cuts, polyimide tape, commonly referred to as Kapton, is ideal for high-temperature applications and strongly protects against water damage and abrasion. It also showcases exceptional electrical properties.

Water-Swelling Tape:

Although initially more costly, water-swelling and water-blocking tapes efficiently absorb liquids and expand to fit the cable size upon water contact, preventing additional ingress. This effectively shields internal wires from potential water damage.

PTFE Tape:

Best used in environments with high friction and elevated temperatures, polytetrafluoroethylene (PTFE) is a robust synthetic fluoropolymer ideal for rigorous industrial needs. It also helps minimize high-speed data loss between cable jackets and shielding.

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Paper Tape:

Often placed between a cable jacket and shield for easy removal, paper tape is typically twisted into circular formats to fill spaces in high-voltage power cables. While inexpensive, it doesn't withstand consistent flexing well and may fail when exposed to heat or moisture unless treated accordingly.

boPET Tape:

Delivering high tensile strength and durability, boPET is a polyester film made from biaxially-oriented polyethylene terephthalate, offering chemical stability, transparency, reflectivity, and electrical insulation. Mylar is a widely-known brand of this material.

Plastic:

Available in an array of sizes, plastic filler typically reduces electrical interference such as crosstalk. While more expensive and less flexible than other options, polyethylene is a widely-used thermoplastic filler that is lightweight, making it suitable for longer cables.

Foam:

Highly adaptable and effective for filling small gaps, foam is more workable than harder materials and assists in maintaining cable shape.

Cotton:

Though not ideal for demanding applications, cotton is a cost-effective filler used in longer wiring strands. It allows for greater flexibility compared to harder materials and can be treated with additives for enhanced fire protection.

Steel:

This filler is commonly utilized in applications demanding additional strength. Capable of being tied off at an assembly's end, steel shifts the force away from conductors to a structural element within the assembly.

Kevlar:

This heat-resistant para-aramid synthetic fiber features a tightly bonded molecular structure, making it exceptionally strong. Although it tends to be pricier, Kevlar is ideal for enhancing durability in longer cables, including those used for fiber optics.

In addition to these popular choices, several other options exist for instances requiring specific performance benefits such as enhanced flexibility and electrical stability.

Not sure what cable filler options to include in your cable assembly? For answers to all your electrical project questions, start a conversation with CAI today.

Modified Polyphenylene Ether, mPPE Insulated Wire & Cable ' Environmentally Friendly

Galaxy is a leading supplier of custom and stock Modified Polyphenylene Ether (mPPE) wires or cables. Galaxy can supply mPPE wires and cables in various AWG sizes, voltage ratings, compounds, shielding options, and conductor counts. mPPE is recognized as environmentally friendly because it is 100% recyclable.

What is Modified Polyphenylene Ether / mPPE?

Modified Polyphenylene Ether, or mPPE, is a thermoplastic material developed initially for the automotive sector. Its superior dielectric properties allow for significantly reduced wall thickness, enhancing fuel efficiency by minimizing weight.

Common Types of mPPE Wire or Cable and Industry Applications

mPPE ' Eco-Friendly Wire/Cable Material

Thanks to its recyclability, mPPE boasts a lower environmental impact compared to other wire and cable materials like PVC. It is commonly used for insulation and is both zero halogen and flame retardant. These eco-friendly characteristics, along with its lower weight and superior dielectric properties, make it a compelling choice.

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