What Are Rubber Sheathed Cables?
Rubber sheathed cables feature multiple fine copper strands as conductors, surrounded by rubber insulation and an outer rubber sheath. These flexible, movable cable varieties are engineered for demanding environments where durability and flexibility are paramount.
Common types include:
- General-purpose rubber sheathed flexible cables
- Welding machine cables
- Submersible motor cables
- Radio equipment cables
- Photography lighting cables
What Are Plastic Cables?
Plastic cables, typically using polyvinyl chloride (PVC) or similar polymers, offer reliable electrical insulation with excellent chemical resistance properties. These cables are designed for stable performance across various environmental conditions while maintaining cost-effectiveness for widespread applications.
Key Differences Between Rubber Sheathed and Plastic Cables
1. Material Composition
Rubber Sheathed Cables:
- Insulation and sheath made from natural rubber, styrene-butadiene rubber (SBR), or ethylene-propylene rubber (EPR)
- Multi-strand fine copper conductors for maximum flexibility
- Available with specialized shielding layers (semiconductor rubber or steel-nylon mesh) for enhanced safety
Plastic Cables:
- Insulation primarily made from PVC compounds
- Can feature both copper and aluminum conductors
- May incorporate metal shielding layers or armor for specific applications
2. Performance Characteristics
Flexibility and Mechanical Properties:
- Rubber cables demonstrate superior flexibility and elasticity, maintaining performance even after repeated bending, compression, and deformation
- Plastic cables offer adequate flexibility for fixed installations but can become brittle over time, especially in extreme temperatures
Temperature Range:
- Rubber sheathed cables operate effectively in a wider temperature range (-40°C to 90°C)
- Plastic cables typically function well between -15°C to 70°C, with performance degrading at temperature extremes
Environmental Resistance:
- Rubber cables excel in resistance to UV radiation, oil exposure, and chemical corrosion
- Plastic cables provide good chemical resistance but may deteriorate faster when exposed to oils, solvents, and prolonged UV exposure
3. Application Environments
Where Rubber Sheathed Cables Excel:
- Mobile and portable equipment requiring frequent movement
- Mining operations, particularly in working faces where flexibility and safety are critical
- Outdoor installations exposed to weather elements
- Heavy machinery and equipment subject to vibration and physical stress
- Applications requiring frequent coiling and uncoiling
Where Plastic Cables Excel:
- Fixed indoor installations
- Building wiring systems
- Applications with limited movement requirements
- Cost-sensitive projects with standard environmental conditions
- Underground conduits and protected pathways
4. Safety Features
Rubber sheathed cables, particularly shielded varieties used in mining applications, offer enhanced safety through:
- Semiconductor shielding layers that detect insulation failures before they cause phase-to-phase short circuits
- Ground fault detection capabilities that prevent electrical sparks from contacting air in explosive environments
- Superior protection against electric shock hazards
Plastic cables rely more on external protection systems and proper installation practices to maintain safety standards.
5. Economic Considerations
- Initial Cost: Plastic cables generally have lower material and manufacturing costs
- Longevity: Rubber sheathed cables often demonstrate longer service life in demanding applications, providing better total cost of ownership despite higher initial investment
- Installation: Rubber cables require less protective infrastructure in harsh environments, potentially reducing overall installation costs
Industry Applications by Cable Type
Rubber Sheathed Cables in Practice
Mining Industry: In underground mining operations, rubber sheathed cables are the preferred choice for mobile equipment due to their exceptional flexibility and durability. Shielded rubber cables are mandatory in gassy mines as they work with leakage relays to prevent electrical sparks that could ignite explosive atmospheres.
Heavy Industrial Applications: From port machinery to large-scale irrigation systems, heavy-duty rubber sheathed cables (YC/YCW types) withstand mechanical stress that would damage conventional plastic cables.
Welding Operations: Specialized rubber insulated welding cables (YH/YHF types) handle the unique electrical characteristics of welding equipment while maintaining flexibility in workshop environments.
Plastic Cables in Practice
Building Infrastructure: Plastic insulated cables form the backbone of residential and commercial building wiring due to their cost-effectiveness and adequate performance in protected environments.
Communication Systems: In mining and industrial settings, plastic insulated cables often serve communication and lighting systems where extreme flexibility isn’t required.
Fixed Power Distribution: For permanent installations with minimal movement requirements, plastic cables provide reliable performance at competitive pricing.
Technical Considerations for Selection
When choosing between rubber sheathed and plastic cables, consider these critical factors:
- Movement Requirements: Will the cable experience frequent bending, coiling, or movement?
- Environmental Exposure: What temperature extremes, chemicals, oils, or weather elements will the cable encounter?
- Safety Criticality: Does the application exist in potentially explosive environments requiring enhanced safety features?
- Installation Method: Will the cable be exposed or protected within conduits and cable trays?
- Expected Service Life: What is the anticipated operational lifespan before replacement?
Maintenance and Failure Prevention
Rubber Sheathed Cables:
- Require periodic inspection for surface cracking or hardening
- Can be damaged by prolonged exposure to certain solvents and oils
- May require specialized drying techniques if moisture penetration occurs
Plastic Cables:
- Susceptible to UV degradation when used outdoors without protection
- Can become brittle with age, particularly in temperature cycling environments
- Vulnerable to physical damage if not properly protected during installation