What kind of varnish can you use to insulate wires?
About 95% of all enamel-insulated wires are produced using synthetic varnishes that form high-strength enamel coatings. The most common varnish in the manufacture of wires is Viniflex varnish (VL-931).
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Products intended for wire insulation
First of all, let's figure out how, in fact, you can insulate the wires. And in what cases can this or that product be used.
| The most common is the so-called PVC electrical tape. This product is made of polyvinyl chloride, with a special rubber-based adhesive applied to one of its sides. PVC electrical tape can be used to insulate almost any conductor. Its only serious drawback is the melting point, which at a temperature of about 120⁰C makes the electrical tape plastic and causes it to “drip” from the conductor. But given that most wires also have PVC insulation, electrical tape is quite capable of withstanding the same temperatures as most basic wire insulation. |
| Cotton tape (CB) does not experience such temperature problems. At high temperatures, on the contrary, it dries out and, like a “cocoon,” covers the place where it is applied. But CB electrical tape has another problem. It is hydrophobic and therefore cannot be used in damp and damp rooms, as well as outdoors. |
| In addition, there are insulating tapes based on fiberglass, ordinary fabric, silicone rubber, polyester films and nylon. But they are practically not used at home, so we will not consider them in more detail. |
| In second place in terms of use are the so-called heat-shrinkable tubes. This is a product based on thermopolymers, which, when heated, reduces its size by 2 and sometimes more times. It is used for insulating both small cross-section wires and cable insulation. The only drawback of this material is its poor ultraviolet resistance. Therefore, it is better not to use such material on the street. The exception is black heat shrink, which is more resistant to ultraviolet radiation. In addition, the instructions do not allow the use of such tubes at temperatures above 135⁰C. |
| A variety of screw and clamp terminals are often used to insulate the junction of wires. They provide high-quality connection of wires to each other and their insulation. The most common are screw terminals, Wago terminals, PPE caps, but other options may be used. |
Overview of insulating materials
Today, to insulate bare conductors, it is recommended to use materials such as:
- PVC electrical tape. Has good elasticity. It is used most often and in many practical cases - from installation in a junction box to under the hood of a car. It comes in different colors, making it convenient to color-code wires.
- HB electrical tape. Cotton material is considered obsolete. Good for insulating connections near sources of intense heat. The advantage of CB insulating tape is that it is more resistant to low temperatures during installation, but with prolonged use it can accumulate moisture.
- Heat shrink tube (HERE). Heat shrink is one of the most modern and reliable insulating materials. It is recommended to use it if you need to insulate the junction of electrical wires not only in the house, but also in the ground, as well as in the car. Moreover, if you use heat shrink in several layers or together with electrical tape, then such a connection can work for some time even under water.
- PPE caps. This is not so much a method of isolation as a method of connection. It does not provide protection against moisture penetration, but compresses twisted wires, which meets the requirements for connecting wires (clause 2.1.21, Chapter 2.1 of the Electrical Installation Code). Therefore, PPE caps are great if the length of the exposed section of the core does not exceed the length of the PPE or if you are going to further insulate the cores with heat shrink or electrical tape.
So we have provided the most reliable and popular insulating materials among electricians. Next, we will tell you how to properly insulate exposed contacts with electrical tape, heat shrink and special caps.
Video review of existing insulation methods
Installation of thermal tubes
The advent of thermal tubes with a shrinkage function has significantly expanded the possibilities of insulating wiring not only for domestic purposes, but also for industrial scales.
The sequence of actions for installing the tube has a number of differences:
- The prepared tube is placed on the end of the wire (one of the ends to be insulated or connected).
- After this, the exposed wires are twisted.
- The dimensions of the tube used must exceed the length of the stripped area by 1 cm on each side.
- The tube is advanced along the wires, reaching the twisting point.
The next step is to heat the material using a hair dryer or an ordinary lighter. Heating is carried out in the direction from the edge to the middle of the selected area.
The criterion for the effectiveness of the measure is the narrowing of the outlet of the tube. This method is considered more practical, but deciding which wire insulation is better is quite complicated.
Insulating Wiring Using Tape
The most popular method of insulating electrical wiring is using duct tape.
Regardless of its qualitative composition, all events have a common algorithm:
- After stripping the wires, you need to perform traditional twisting and soldering.
- Immediately before installation, the surface for insulation should be cleaned. There should be no excess particles, dust, oil or drops of moisture on the wire.
- Take a piece of adhesive tape carefully so that dirt, debris, and lipid contaminants from your fingers do not get on the inner surface.
- The strip of material is applied at an angle so as to capture the minimum part of the old insulation and move towards the twisting point.
- Next, you should bend the twist so that it is located on the same plane as the main coating. The next step is to apply another layer of insulating tape, but the direction of movement of the roll changes (towards the main protection).
For a more durable fastening, you should press the tape to the underlying surface, and cut off the excess material using a stationery knife.
After completing the installation work, it is necessary to check the wire insulation using a megohmmeter (in certain sections of the electrical circuit).
When is insulation needed?
- Wire color code. Sometimes you don't have the color of wire you need on hand. No problem - just have the correct color of electrical tape or "thermocouple" and use it to indicate proper cable functionality at both ends.
- Cable insulation – during electrical installation work, accidental damage to the wire insulation can be caused. Usually they do not replace the entire wire, but put a patch on it.
- The housing can touch not only cable insulation, but also connectors that do not have their own insulation, or, for example, need to be protected from mechanical damage and moisture.
- Strengthening connections - sometimes the outer sheath of the power cord of a device is damaged or frayed. Then such a cable hangs on two or three wires without a protective layer. It is only a matter of time before there is a complete breakdown. There are also two options: replace the power cord or try to strengthen it at the site of damage.
- It happens that due to a large number of devices or cables, there is a bundle of wires in a certain area. They can be laid in the cable, secured with cable ties, covered with a frame or, if it is a short section, they should be wrapped with a heat shrink sleeve.
How can I seal the headphone wire?
Each twist is insulated with tape, electrical tape or heat shrink tubing. To wire
does not break, a bandage made of harsh thread is placed at the connection.
For aesthetics, tape is wound on top or heat-shrinkable tubing is stretched. Of all the methods considered, only soldering the wire
will ensure high-quality sound
from the headphones
.
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