In today’s highly demanding electrical industry, General Purpose Silicone Rubber Cables have made a name for themselves due to their high-temperature resistance, flexibility, and unique properties.
These cables are versatile, dependable, and used across various industries, including lighting, appliances, and industrial machinery. But what makes them different from other types of cables? Let's break it down.
Silicone rubber is a thermosetting elastomer (a material that becomes permanently hard when heated), and it stands out in the cable world for one major reason: it’s not carbon-based, like most other rubbers.
Instead, silicone rubber is based on silicon, giving it distinctive properties that make it an excellent choice for high-temperature applications.
It is classed as a halogen-free material, meaning it doesn’t release toxic gases when exposed to fire.
The chemical makeup of silicone rubber also gives it several other notable advantages, which makes it ideal for general-purpose cables. Unlike other materials like Chlorinated Polyethylene (CPE), silicone rubber can withstand a much broader range of temperatures.
General Purpose Silicone Rubber Cables bring several critical features to the table:
Wide Operating Temperature Range:
This is perhaps the most remarkable feature. Silicone rubber cables can operate at temperatures as high as 150°C to 180°C, making them perfect for high-temperature environments. At the same time, these cables stay flexible even in sub-zero conditions, with some compounds able to function as low as -50°C or even -70°C.
Flexibility:
Silicone rubber cables remain flexible at both high and low temperatures, making them suitable for dynamic applications where cables are subject to movement or bending.
Good Electrical Properties:
The electrical insulation properties of silicone rubber make these cables ideal for low-voltage applications, such as internal wiring in appliances or industrial machinery.
Ozone Resistance:
Another standout feature is the excellent ozone resistance, which helps ensure longevity, especially in outdoor or high-pollution environments.
Low Mechanical Strength:
While silicone rubber has many advantages, one downside is its relatively low mechanical strength. It doesn’t offer high resistance to wear and tear or abrasion. In many cases, a glass braid is added over the insulation to provide extra protection.
Halogen-Free:
Silicone rubber is inherently halogen-free, which means it doesn’t emit harmful or toxic gases during combustion, making it a safer choice in the event of a fire.
Both General Purpose Silicone Rubber Cables and Chlorinated Polyethylene (CPE) cables are used in a variety of environments, but they serve different purposes and have different characteristics.
Temperature Range: Silicone rubber cables can withstand much higher temperatures than CPE cables. While CPE cables are resistant to heat and flame, they don't operate effectively in the extreme temperatures silicone cables can tolerate.
Mechanical Strength: CPE cables have superior mechanical strength compared to silicone rubber cables. They are more resistant to abrasion and physical wear, making them a better option in harsh environments where cables might be subject to significant mechanical stress.
Halogen-Free: Unlike CPE, silicone rubber is naturally halogen-free, which is an advantage in industries that prioritize fire safety.
The process of making General Purpose Silicone Rubber Cables involves several steps to ensure that the material can withstand its demanding operating conditions. Here’s how it typically works:
Compounding the Silicone: Raw silicone gum is mixed with various additives, including reinforcing fillers like silica. These fillers are carefully chosen to boost the rubber's electrical and mechanical properties.
Other components like vulcanizing agents (which help the rubber set into its final form) and coloring pigments are also added during this phase.
Extrusion: The compounded silicone rubber is then fed into an extruder, a machine that shapes the rubber into a cable form around the wire conductors.
This step is carried out using a single-screw extruder, which ensures the rubber is evenly applied.
Curing: Once the silicone rubber is extruded, it needs to be cured to develop its final properties. This is done using live steam or an infrared curing tunnel.
The curing process cross-links the rubber, making it heat-resistant and flexible.
Post-Curing: To improve the heat resistance and ensure the long-term stability of the cable, the silicone rubber goes through a final post-curing process.
This is especially important for cables designed to operate in extreme environments.
Thanks to their high-temperature tolerance and flexibility, Silicone Rubber Cables find application in several industries and devices. Some of the most common applications include:
Lighting and Lamps: These cables are frequently used in enclosed lamps and other lighting fittings where high temperatures are a concern.
Appliances: Many household and industrial appliances, like ovens or heaters, rely on silicone rubber cables for internal wiring that can withstand high heat.
Industrial Processes: In factories and processing plants, machines often operate at high temperatures. Silicone rubber cables are used to ensure continuous, safe operation in such conditions.
Railway Rolling Stock: Silicone rubber cables are increasingly being used in the latest generation of railway rolling stock, thanks to their durability and ability to handle fluctuating temperatures.
Offshore and Marine Installations: Silicone rubber is used for high-temperature locations on ships and offshore installations, where cables need to withstand harsh environments.
General Purpose Silicone Rubber Cables are regulated by several international standards, ensuring they meet strict safety and performance requirements:
IEC 60092: This standard applies to electrical installations on ships and offshore units.
IEC 60245: Covers rubber-insulated cables for industrial use.
BS EN 50382: Defines silicone rubber cables for railway rolling stock.
BS EN 50525: Specifies silicone rubber cables for general wiring.
BS 7655: Deals with cross-linked elastomeric insulation, including silicone.
Def Stan 02-527: A British standard for naval electrical cables, including silicone rubber insulated ones.
When you need a high-performance cable that can handle extreme temperatures, resist ozone, and provide flexibility even in the toughest conditions, General Purpose Silicone Rubber Cables are an excellent choice.
Their combination of heat resistance, low-voltage operation, and ability to perform in both hot and cold environments makes them a go-to solution for industries ranging from lighting to marine applications.
Although they may not be as mechanically robust as some other materials, like CPE, their flexibility and halogen-free nature offer significant advantages in many settings.
Whether you’re wiring a high-temperature oven, installing lighting fixtures, or outfitting the internal systems of a train, these cables deliver the performance and reliability you need.
In a world where high temperatures and tough environments are the norm, General Purpose Silicone Rubber Cables provide an efficient, reliable, and safe solution.
Their ability to function at extreme temperatures, combined with their flexibility and electrical properties, makes them indispensable across various industries.
Whether you're dealing with industrial machinery, lighting fixtures, or railway systems, these cables will help ensure smooth, uninterrupted operation.
Their status as halogen-free and fire-resistant materials, alongside their widespread use in demanding applications, ensures that silicone rubber cables are here to stay as one of the best solutions for high-temperature environments.
Choose General Purpose Silicone Rubber Cables when you need performance, reliability, and safety.
