A car is a work of engineering marvel, as it relies on multiple different components working together towards one single goal: To move. All of these components have to be perfectly in sync for a car to work, and the one thing that keeps them in sync is the automotive cable system. Working much like the nerves in our body, the cable system delivers power as well as information in the form of electricity throughout the car to make sure that all components are working properly.
Advances are being made to improve automotive cable systems or wire harnesses. One of the most important breakthroughs in the industry is the use of polyethylene liner for automotive cable systems. This article will provide the information you need about polyethylene liner, specifically its specifications and applications.
What are Automotive Cable Systems
An automotive cable system is a complex system consisting of cables and terminals. The cables will transmit electrical charges throughout the car to make sure that components have the power to run. The automotive cable system will also enable the driver to control all aspects and functionalities of the car from the control dashboard, enabling them to make decisions with ease.
Automotive cables are often made with copper or aluminum, and there is a liner on the outside to insulate the electrical current from human touches. Without this insulating liner, touching the cable can be deadly. This liner is often made from polyethylene (PE) or polyvinyl chloride (PVC), two very popular thermoplastic materials.
Polyethylene Liner Applications in Automotive Cable Systems
Polyethylene liner is a very popular choice for most automotive cable systems, owing to the fact that the material can provide a great deal of insulation while still being very flexible and lightweight. PE cables are also highly resistant to not just water but also oil, UV lights, and abrasion, making them a particularly durable option that will last long.
The anti-abrasive nature of PE liner makes it a particularly good choice for automotive cable systems. Cars have to move around a lot, and this means that the cables will receive a lot of frictional and abrasive damage from the bumps and stops along the road. If the liner is damaged, the electrical current within the cables might not be contained, resulting in an open circuit that can be very dangerous to anyone who touches it.
Polyethylene Liner Specifications in Automotive Cable Systems
On its own, polyethylene is a great thermoplastic material that has plenty of benefits for a wide range of products and industries. The most important specifications of polyethylene will be illustrated below.
Summary
Flexible, translucent/waxy, weatherproof, good low-temperature toughness (to -60’C), easy to process by most methods, low cost, good chemical resistance.
PHYSICAL PROPERTIES
Tensile Strength 0.20 – 0.40 N/mm²
Notched Impact Strength no break Kj/m²
Thermal Coefficient of expansion 100 – 220 x 10-6
Max Cont Use Temp 65 oC
Density 0.944 – 0.965 g/cm3
RESISTANCE TO CHEMICALS
Dilute Acid: Strong
Dilute Alkalis: Strong
Oils and Greases: variable
Aliphatic Hydrocarbons: Weak
Aromatic Hydrocarbons: Weak
Halogenated Hydrocarbons: Weak
Alcohols: Strong
Other Types of Materials for Automotive Cable Systems’ Liner
PE is one of the best materials for the liner in automotive cable systems, but it certainly is not the only choice either. There are plenty of good choices that you can also take into consideration.
Polyvinyl Chloride (PVC)
PVC is another ubiquitous thermoplastic material that is used in pretty much all consumer goods in the modern world. PVC can be used as the liner for automotive cable systems due to how flexible and cost-effective it is. The downsides of this material are that it does not do well against UV light, and it offers worse protection against abrasion compared to PE.
Rubber
A naturally occurring material, rubber is used in a vast range of industries. Its stretchy and highly flexible nature enables this material to become one of the most popular choices for liners in automotive cable systems. However, rubber is also quite an expensive material that you will have to pay some premiums to work with, so it is not a scalable option for the most part.
Teflon
Otherwise known as Polytetrafluoroethylene, Teflon is another great material to make cable liners for automotive lining systems. Teflon is super flexible and non-flammable, enabling it to endure high-stress situations with ease. This material also boasts amazing anti-oil and fluid capabilities. It is, however, quite expensive, and is not readily available as PVC or PE.
Silicone
One of the newer materials to be used as cable liners, silicone already proves itself to be a great choice thanks to the amazing flexibility it has as well as its ability to resist UV light. However, it is not suitable for high-stress environments, as silicone liner does not fare well against abrasive damage, which means that it will become more frayed as you use the car.
Why Choose Professionally Made Wire Harness
Wire harnesses or automotive cable systems are the nervous systems of your car. This system must not fail, or else the car cannot work properly, putting you in dangerous situations. Thus, you should consider letting the experts help you with designing and delivering high-quality wire harnesses made from a wide range of materials. With over 20 years of experience in the field, Art Tangent is here to help! We offer wire harnesses of many different components within your automobile to deliver nothing but the best results. Contact us for more information!
Using PE liner in automotive cable systems offers not just better protection against a wide range of environmental hazards, but also helps to keep your production costs low. PE is also a material with high tensile strength, enabling it to accomplish some impressive workload.
Reference:
A New Approach in Automated Cable Assembly
One Response
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