feature | Wire and cable
insulation system, is an environmentally safe (tin-free) solution enabling production of high-quality LV cables and insulated overhead conductors at high output rates. The fire performance portfolio includes Unigard flame-retardant compounds in a choice of halogenated or non-halogen formulations. Dow says that these compounds demonstrate flame retardance exceeding industry standards, low smoke, good physical proper- ties and ease of cable manufacturing. The non-halogen formulations demonstrate lower smoke, no corrosivity or toxicity and are more environmentally friendly. Dow Axeleron CX 1258 NT compound (CPD) is
claimed to offer improved electrical performance with a lower dissipation factor. In addition, it provides ease of mixing with rheology compatible with high-density polyethylene (HDPE) for manufacturing consistency, as well as physical properties that enable construction of higher-quality cables with lower signal loss.
Below: AGC’s Fluon ETFE C88AXMP HT grade is supported with a full range of colour masterbatches
Future developments Tarimo also highlights some of the company’s future cable sector developments. “Dow has recently passed all European requirements for its new, advanced TR-XLPE medium-voltage cable insulation compound,” he says. “We are working toward widespread adoption of this compound for MV cables in Europe. Since 2013, the compound has been made into over 1 billion feet of cable in North America. Field-testing of the previous generation TR-XLPE along with Accelerated Life-Cycle Testing (ACLT) of the advanced compound, suggest that expected service life of cables made with this com- pound could far exceed 40 years.” Katie Sprick, Product and Development Engineer at
AGC Chemicals Americas, agrees that wire and cable applications are becoming more demanding and require higher performance materials. “These include growth areas such oil and gas downhole cable, automotive/ HDD under the hood, aerospace, telecommunications and industrial applications,” she says. “These wires and cables have to withstand exposure to increased temperatures and harsh chemicals, as well as abra- sion. Other influences include conductivity require- ments and shrinkage prevention, as well as the need for lighter weight materials, the ability to create thin-walled constructions, and increased service life. This means cable materials require enhanced mechanical strength, chemical and temperature resistance, flame retardancy, as well as prevention of spark-outs and breakage, and improved processability.” The latest product
50 COMPOUNDING WORLD | May 2016
from AGC pitched to meet these needs is Fluon EFTA C88AXMP-HT, which the company says has the highest MFR and temperature rating available. “The new compound is an ultra-heat-resistant grade that maintains performance characteristics at temperatures up to 200 °C without the need for cross-linking,” says Sprick. “It is ideal for industrial and automotive wire and cable insulation, as well as under-floor heating cables, because it provides improved crack and abrasion resistance and enhanced mechanical strength.” The company says the compound is 20% less dense than fluorinated ethylene propylene (FEP), which reduces the amount of product required for applica- tions. In addition, its high melt flow rate provides fast, highly efficient processing line speeds, and one product grade is suitable for all wire size cross sections (0.3-10 mm2
). C88AXMP-HT is also said to offer enhanced
mechanical strength, and supported with a full range of compatible colour masterbatches. The grade is tested to German automotive LV112 class F and meets automotive FLUR specifications. The new material is part of the Fluon fluoropolymer
resins and reinforced compound range from AGC. These products are designed to protect and optimise high performance wire and cabling such as wire insulation, cable sheathing, tubing and moulded parts for automo- tive, industrial, aerospace, transit and appliance applications.
Specific applications for Fluon fluoropolymer resins
have also included controlling shrinkage of perfluoro- alkoxy (PFA) in cable applications. PFA cable jackets can be difficult to work with when adding connectors because the PFA tends to shrink, while the other layers of the construction do not. AGC says that it customises sets of speciality fillers and pigments to control shrinkage in its PFA-based Fluon compounds for cable constructions.
Oil & gas demands Cables used in oil and gas recovery are a further example of where Fluon compounds are meeting demands for high performance. AGC says Fluon ETFE compounds that contain conductive, strengthening and reinforcing fillers are helping downhole cables better tolerate extreme temperatures, pressures, harsh chem- icals and volatile weather conditions. These cable components can withstand depths of 25,000 feet (7,620 m), 15,000 psi, can resist abrasion and bending fatigue, have an ultra-smooth outer surface, and endure torsion, tension and extreme temperature cycling. According to AGC, Fluon ETFE can be compounded with fillers that dissipate the electrical charges that
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