What are the characteristics of the insulation structure design of rubber cord and cable

In the cable industry, the choice of insulation material for Rubber Cord and Cable is crucial. Rubber, as a commonly used insulating material, has a wide variety of types, including natural rubber, synthetic rubber and butyl rubber, each with unique performance advantages. Natural rubber can maintain good insulation performance over a wide temperature range due to its excellent heat resistance and cold resistance. Under extreme climatic conditions, whether high or low temperature, the natural rubber insulation layer can effectively prevent current leakage and ensure the reliable operation of the cable. Although synthetic rubber is slightly inferior to natural rubber in terms of heat resistance and cold resistance, its relatively lower cost and the conventional environmental requirements that can be met after formula adjustment make it a cost-effective choice. Butyl rubber is favored for its excellent oil resistance and acid and alkali resistance. It is especially suitable for environments with high chemical corrosion requirements such as the petrochemical industry and automobile manufacturing. It can effectively resist the erosion of oils and chemicals and ensure that the insulation performance of the cable is not affected.

The thickness design of the insulation layer is one of the key factors to ensure the insulation performance of the cable. According to national standards, the insulation thickness of rubber-sheathed cables shall not be less than 0.6mm, which is a basic safety guarantee. However, in practical applications, the requirements for insulation thickness in different scenarios vary significantly. In high-voltage power transmission, in order to withstand higher voltage levels and prevent insulation breakdown caused by excessive electric field strength, the insulation thickness is usually required to be above 2-3mm. For example, in large industrial power grids, the insulation layer thickness of high-voltage cables is generally thicker to ensure stable operation under high-voltage environments. In low-voltage power transmission, due to the low voltage, the requirements for insulation performance are relatively low, so the insulation thickness can be appropriately reduced to reduce the weight of the cable, reduce costs, and facilitate installation and laying.

The manufacturing process of the insulation layer also has a significant impact on its performance. The use of advanced rubber extrusion processes, such as rubber extrusion continuous production lines, can ensure the uniformity and stability of the insulation layer. During the rubber extrusion process, by precisely controlling the extrusion temperature, pressure and speed of the rubber material, the insulation layer is ensured to be tightly wrapped around the conductor to avoid defects such as bubbles and impurities. These defects may lead to a decrease in insulation performance and even cause safety hazards. In addition, the rubber extrusion process can effectively enhance the bonding force between the insulation layer and the conductor, improve the overall mechanical strength of the cable, and prevent the insulation layer from separating from the conductor under external forces such as bending and stretching.

In order to improve the aging resistance of the insulation layer, a variety of additives are usually added to the rubber material. Antioxidants can effectively inhibit the oxidation reaction of rubber under the influence of environmental factors such as oxygen and light, slow down the aging of rubber, and extend the service life of the insulation layer. Ultraviolet absorbers can absorb ultraviolet rays, reduce the damage of ultraviolet rays to rubber molecules, and prevent the insulation layer from becoming hard and brittle due to ultraviolet rays. In addition, the addition of flame retardants makes the insulation layer less likely to burn in the event of a fire, thereby preventing the fire from spreading along the cable and buying precious time for personnel evacuation and fire extinguishing.