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Wire and cable: some new developments
Wire and cable: some new developments There are a number of issues to be considered when selecting a compound for wire and cable applications. Plastics Additives & Compounding looks at some recently undertaken research in the trends in the market for wire and cable and some technical developments in the area.
The total U.S. market for polymeric materials used in wire and cable was around 808 million kg (1,782 million pounds) in 2003, according to research recently undertaken by Business Communications Co. Inc. (BCC) specialists in industry research and technical market analysis. In a soon-to-bereleased report, RP-181 Wire and Cable: Polymer Materials and Structures, the company predicts that the US market should grow to around 948 million kg (2,089 million pounds) in 2008 at an average annual growth rate (AAGR) of about 3.2%. BCC says that the largest segment, thermoplastic resins, was 665 million kg (1,467 million pounds) in 2003 and is expected to rise at an AAGR of 3.3% to 781 million kg (1,722 million pounds). They include fluoropolymers, polyolefins
(primarily polyethylene and its copolymers but also including a small but growing quantity of polypropylene), PVC, and some other thermoplastics. The greatest volume is in PEs and PVC at about 333 and 254 million kg (735 and 560 million pounds), respectively, in 2003. Thermosetting elastomers have an estimated market of about 104 million kg (230 million pounds) in 2003, says BCC. This is predicted to grow at a somewhat lower rate of 2.8% AAGR to 120 million kg (264 million pounds) in 2008. Ethylene-propylene synthetic rubbers, mostly EPDM, have been the fastest growing thermosets recently and have now passed natural rubber in wire and cable applications. The research highlights how thermoplastic elastomers (TPEs) have become increasingly popular in wire and cable
Table 1: Overall volume of polymers and flame retardants used in US wire and cable by material categories (2003-2008) - million kg (million pounds) Source: BCC Inc. Material
2003
2008
AAGR % 2003-2008
Thermoplastic resins
665 (1467)
781 (1722)
3.3
Thermosetting elastomers
104 (230)
120 (264)
2.8
Thermoplastic elastomers
32 (70)
38 (83)
3.5
Polymer optical fibre
7 (15)
9 (20)
5.9
808 (1782)
948 (2089)
3.2
Total
Plastics Additives & Compounding May/June 2004
32
applications and have both grown on their own and taken some market share from other materials, both thermoplastic resins and thermosetting elastomers. BCC estimates the total US market for wire and cable TPEs in 2003 to be about 32 million kg (70 million pounds), growing at 3.5% to 38 million kg (83 million pounds) in 2008. Other trends in the market include the use of polymer optical fibre (POF) - a plastic used instead of glass to make a fibre optic conductor. However, BCC points out that it is still a rather small market at this time compared to glass optical fibre. Nevertheless POF is cheaper and easier to install and remove, but its growth was held back by its chief drawback of only being feasible in relatively short lengths. Several new short-length applications, such as in automotive and inside-the-home wiring, are being developed and will eventually produce good growth for POF, from about 7 million kg (15 million pounds) in 2003 to 9 million kg (20 million pounds) in 2008. The U.S. market for polymeric materials used in fabrication of wire and cable is large and has been considered to be a mature one for several years, reports BCC. The company adds that technological changes that are affecting the industry have primarily been in communications, where fibre optics continue to replace copper wire and in plenum wire where special insulation is required to withstand potential high temperatures and toxic combustion products. However, another major trend likely to affect the market is the rapid growth of wireless technology.
ISSN1464-391X/04 © 2004 Elsevier Ltd.All rights reserved.
Wire and cable Lead-free technology US company Teknor Apex has introduced a number of new compounds for the wire and cable industry. According to the company, Apex® 80853F insulation compound has become the first lead stabilizer-free PVC product to achieve Underwriters Laboratories listing for continuous service at 90°C in wet locations in wire designated in the National Electrical Code (NEC) as THWN-2. The company explains that although manufacturers of conventional wire and cable compounds have used lead stabilizers to ensure the retention of electrical properties, the new Apex compound provides insulation so effective that it actually replaces lead-containing formulations. Lead-based heat stabilizers provide PVC polymer with high resistance to thermal degradation, which can compromise electrical performance. Yet while most insulators based on standard leadcontaining PVC compounds are restricted for use only with black formulations and in wire above a certain minimum gauge, the new Apex 80853F compound is claimed to be unrestricted as far as colour or gauge is concerned. Teknor Apex says that it believes that Apex 80853F to be the only no-lead vinyl compound rated for wet-location use at 90°C continuous service available from any supplier, whether merchant or captive compounder. Since the typical THWN application presents the worst-case scenario in that its vinyl insulation is thinnest, the outstanding electrical properties of this new compound make it suitable for a wide range of other uses as well, says the company. THWN-2 wire is nylon-jacketed, vinylinsulated building wire used in industrialequipment applications such as control wires for motors. Other wet-location uses anticipated for the new compound include machine-tool wiring (MTW), appliance wire (AWM), and outdoor flexible cord (STW). Teknor Apex adds that it received the 90°C listing for Apex 80853F from UL only months after the compound was listed for continuous service at 75°C and
Semi-flexible conduits have solved a wire and cabling problem in Chicago, USA. (Photo:Teknor Apex)
105°C in wet and dry locations, respectively.
Semi-flexible conduit Teknor Apex has also taken proven technology in cable compounding and adapted it for semi-flexible conduits to solve another problem facing the wire and cable industry. New technology involving Fireguard® Low-Smoke/Zero Halogen, or LSZH™, compounds is now enabling installers of cable in municipal, public-utility and similar projects to save time and costs by using semi-flexible plastic conduit while eliminating concerns about excessive smoke generation in fires. Under a pending patent applied for jointly by Teknor Apex and cabling system supplier Arnco Corporation, Arnco has used a specially formulated Fireguard LSZH compound to develop Fiber-Guard® LSZH conduit, a coilable product that contains no halogens either in the base polymer or in flame retardant
33
additives. The first application of the new conduit is in an 8km (5 mile) project beneath the city of Chicago in the USA According to Robert Washburn, Arnco's vice president of R&D, unlike metal conduit, which is shipped in standard 3m (10 ft) sections and must be assembled onsite, semi-flexible plastic conduit comes in continuous coils that can be fed through the city substructure with minimal disruption of surrounding components. In addition, he adds that continuous conduit permits the use of new fibre optic cable blowing techniques, which are precluded by the enormous number of joints required in any sizeable installation of metal conduit. The Chicago project involved running cable through the stations and tunnels leading into the city centre on one route of the Chicago Transit Authority (CTA) railway system. CTA requirements call for use of low-smoke/zero-halogen coiled conduit in order to increase the visibility of exit areas in the event of a fire and to
Plastics Additives & Compounding May/June 2004
Wire and cable as telecommunications, data communications, cable television, and electrical utilities."
PVC alternative
Low-Smoke/Zero Halogen compounds have been used to produce semiflexible conduits for installing cables. (Photo:Teknor Apex)
reduce the toxic effects and corrosion caused by acid gases emitted as combustion byproducts. According to Arnco, Fiber-Guard LSZH conduit provides the CTA with the best of both worlds. Most importantly, it helps ensure public safety in the event of a tunnel fire. At the same time, it has contributed to the economical and ontime completion of a project that would otherwise have entailed tedious, labourintensive 'one-stick-at-a-time' assembly. Fireguard® is a Teknor Apex tradename for compounds that meet stringent low-flame, low-smoke requirements for wire and cable insulation and jacketing. While most Fireguard products are PVC-based, Fireguard LSZH compounds are polyolefin-based, completely halogen-free formulations. They were originally developed for insulation and jacketing of copper and fibre optic cable for communications and data transmission. "While Fireguard LSZH compounds have been used successfully in the U.S., our main goal in developing them was to support companies that manufacture in or distribute to Europe, where smoketoxicity restrictions are particularly
stringent," says Donald G. Ouellette, industry manager for Teknor Apex. "To transfer this technology to applications in conduit, we adapted the Fireguard LSZH formulation for use in the process of extruding tubing." The CTA installation is just the first of what Ouellette envisages to be numerous uses of Fireguard LSZH compounds in conduit. "We see possibilities in conduit used by natural gas distributors, cable TV companies, telecommunications providers, and electrical utilities," he says. "Unlike traditional materials used for plastic conduit tubing, Fireguard LSZH compounds do not emit the type of combustion byproducts that have raised concerns about toxicity." The new Fiber-Guard LSZH conduit fits right into what Arnco calls The System. Arnco says that it has created a synergistic approach to the challenges of cable installation. To make installations faster, more precise, and more cost-efficient, the company adds that it has developed a system of standard and custom-built conduit, couplers, cable-placing equipment, pull tapes, chemicals and accessories for use in industries as diverse
Plastics Additives & Compounding May/June 2004
34
GE Advanced Materials has introduced a new family of flexible NORYL® modified-polyphenylene ether (MPPE) resin as an alternative to polyvinyl chloride (PVC), flame-retarded polyethylene (FR-PE), and thermoplastic polyurethane (TPU) in wire-coating applications for the direct-current (DC) cord and plug segments of the consumer electronics industry. The company says that the new products - NORYL WCD910 and NORYL WCP860 resins have passed bending-strength tests by charger manufacturers, address eco-label flame-retardant application concerns, and contain no halogens, such as chlorine, which can break down into dioxins and toxic, highly acidic gasses when burned. The new GE resins are also claimed to offer a lower specific gravity than FR-PE and TPU - weight reductions of 20-30% are achievable - as well as faster extrusion rates for potentially higher productivity and lower systems costs. According to the company, NORYL WCD910 and NORYL WCP860 resins address several important needs of the electronics cord/plug segment. These include the increased use of nonhalogenated compounds particularly in Europe and Asia, as well the need to reduce or eliminate the use of heavy metal pigments. Additionally, there is strong incentive to use polymers that can easily be recycled - both in the plant and at the endof-component life. GE Advanced Materials adds that both materials suppliers and OEMs in these highly competitive segments are extremely interested in opportunities for costeffective environmental solutions beyond those that currently exist. According to the company, the new flexible NORYL resin grades have been designed to help meet these and other changing needs of the electronics, electrical, computing, and telecommunications sectors in a number
Wire and cable Crosslinking by electron beam applications, such as telephone wire, aircraft wire, hookup wire, appliance wire, automotive wire, power cable, marine cable, communication cable, fibre optic cable, battery cable and welding cable to resist high temperatures and corrosive diesel, oil and hydraulic fluid. According to E-Beam Services, the process crosslinks wire and cable, in the finished form, without the use of chemicals or other substances that could degrade the quality and integrity of the final product.The crosslinking process does not require the use of additives or heat.The company adds that the process can accommodate a wide range of jacket materials and wall thicknesses without the need for auxiliary processing equipment.This avoids the problems and limitations associated with thermochemical crosslinking. E-Beam Services adds that the crosslinked wire and cable is not dependent on extrusion parameters, because the process takes place off-line and in the solid state.The company says that the high speed continuous crosslinking process yields an accurate, High performance wire and cable products are crosslinked by a high energy e-beam process for better chemical and moisture resistance.
reliable, uniform, dimensionally stable output.The process is said to work with jacketing materials as diverse as compounds
A high energy electron-beam crosslinking process can permit
based on chlorinated polyethylene, chlorosulphonated
wire and cable manufacturers and OEM product designers to
polyethylene, polyethylene, ethylene-vinyl acetate, polyvinyl
achieve good moisture and chemical resistance, according to
chloride, ethylene-tetrafluoroethylene, polyvinylidene fluoride,
US company E-Beam Services.The company says that the high
Neoprene rubber and ethylene-propylene rubber.
performance crosslinking process improves the physical
Contact:
properties of wire and cable products used in single- and dual-
E-Beam Services
wall applications. In addition, it can be used in speciality product
Tel: +1 877 413 2326
of ways. They are non-halogenated, contain no heavy-metal pigments, offer broad thermal performance, and are lighter and more flexible than many competitive thermoplastics. GE Advanced Materials adds that because they have higher flow characteristics, they can process faster for potentially increased productivity and reduced systems costs compared with FR-PE and TPU. NORYL WCD910 and NORYL WCP860 resins are the first in a new line
of MPPE products from GE Advanced Materials specifically developed for wirecoating applications. NORYL WCD910 resin is formulated for use in DC cords, while NORYL WCP860 resin is formulated for use in plug applications. In 2004, GE says that it plans to unveil new halogen-free flame-retardant (VW-1) versions of these materials for applications that require added FR protection. GE Advanced Materials believes that the new flexible NORYL resin grades are also good potential candidates for a variety of
35
consumer electronics applications. These include video tape recorder (VTR) cameras; radio/cassette, portable CD, micro-disk (MD), MP3, and DVD players; video/TV games; and soundsystem components. In the computing area, the new GE products are expected to be used in plug and cord applications for desktop and notebook computers, personal digital assistants (PDAs), faxes, portable personal computers (PPCs), printers, scanners, and digital cameras. In telecommunications,
Plastics Additives & Compounding May/June 2004
Wire and cable GE anticipates the flexible MPPE resins to make inroads into application areas such as mobile phone accessories and cordless phones. According to Elly Burghout, NORYL resin product manager, GE Advanced Materials, NORYL WCD910 and NORYL WCP860 resins are meeting highly specific needs. "The electronics industry needed a tough, eco-sensitive resin technology with excellent insulating properties, broad chemical resistance, and superior processability - and there was a huge void in terms of what was available," Burghout said. "So we determined that our modified PPE offered the best balance of properties, and then tailor-made two new products to meet these needs and more. In the process, we created a totally new family of NORYL resins for wire-coating applications. The initial success of these materials has been excellent and we are currently looking to translate the products into new areas. Automotive is particularly interesting," Burghout added.
Low voltage power cable ExxonMobil Chemical has introduced a new linear low density polyethylene (LLDPE) resin, LL 4004EL, for lowvoltage power cable insulations. The company says that the resin is available throughout the world and provides the cable manufacturer with a balance of crosslinking speed and ease of processing for cost-competitive cable constructions. "Due to optimization of its antioxidants and improved polymer characteristics, this resin has been especially designed for Silane cross-linking technology, where crosslinking speed and processability are key," said Malcolm J. Kaus, ExxonMobil Chemical Company Global PE Products Technology Manager. "We believe these improvements will provide a cost-effective alternative for cable manufacturers." ExxonMobil says that LL 4004EL resin has been field-tested for two years and is suitable for processing in both one-step (Monosil) and two-step (Sioplas) process technology.
Dyneon has expanded its product line of fluoropolymer raw materials for the wire and cable industry.
Plastics Additives & Compounding May/June 2004
36
ExxonMobil Chemical LDPE and LLDPE grades have been used successfully for more than 15 years in wire and cable silane technology. According to the company, continual quality testing, along with controlled shipping logistics, ensures uniform, consistent products. Wire and cable manufacturers will benefit from increased efficiency of their cable production. Dyneon has expanded its product line of fluoropolymer raw materials for the wire and cable industry. The company says that it has added Dyneon™ PVDF to go with its PTFE, FEP, ETFE, PFA and THV™ FP products. The materials are said to have universal chemical resistance and are suitable over a broad range of temperatures. They are used primarily in the automotive, aerospace and chemical industries, for example in sheathing for heating wires in seats, cables for xenon headlights and for lambda sensors in exhaust gas systems. They can also be used for high speed data lines. Contact: Arnco Inc Tel: +1 440 322 1000 Fax: +1 440 322 1001 E-mail: [email protected] Website: www.arncocorp.com Business Communication Co. Inc. Tel: +1 203 853 4266 E-mail: [email protected] Website: www.bccresearch.com Dyneon GmbH Tel: +49 2131 14 2726 Fax: +49 2131 14 3857 E-mail: [email protected] Website: www.dyneon.de ExxonMobil Chemical Company Tel: +1 281 870 6607 Fax: +1 281 870 6353 Website: www.exxonmobilpe.com GE Advanced Materials Tel: +1 413 448 6959 (Americas & Asia) E-mail: [email protected] Tel: +31 164 29 20 97 (Europe) E-mail: [email protected] Website: www.geplastics.com Teknor Apex Tel: +1 401 725 8000 Fax: +1 401 729 0166 E-mail: [email protected] Website: www.teknorapex.com
The total U.S. market for polymeric materials used in wire and cable was around 808 million kg (1,782 million pounds) in 2003, according to research recently undertaken by Business Communications Co. Inc. (BCC) specialists in industry research and technical market analysis. In a soon-to-bereleased report, RP-181 Wire and Cable: Polymer Materials and Structures, the company predicts that the US market should grow to around 948 million kg (2,089 million pounds) in 2008 at an average annual growth rate (AAGR) of about 3.2%. BCC says that the largest segment, thermoplastic resins, was 665 million kg (1,467 million pounds) in 2003 and is expected to rise at an AAGR of 3.3% to 781 million kg (1,722 million pounds). They include fluoropolymers, polyolefins
(primarily polyethylene and its copolymers but also including a small but growing quantity of polypropylene), PVC, and some other thermoplastics. The greatest volume is in PEs and PVC at about 333 and 254 million kg (735 and 560 million pounds), respectively, in 2003. Thermosetting elastomers have an estimated market of about 104 million kg (230 million pounds) in 2003, says BCC. This is predicted to grow at a somewhat lower rate of 2.8% AAGR to 120 million kg (264 million pounds) in 2008. Ethylene-propylene synthetic rubbers, mostly EPDM, have been the fastest growing thermosets recently and have now passed natural rubber in wire and cable applications. The research highlights how thermoplastic elastomers (TPEs) have become increasingly popular in wire and cable
Table 1: Overall volume of polymers and flame retardants used in US wire and cable by material categories (2003-2008) - million kg (million pounds) Source: BCC Inc. Material
2003
2008
AAGR % 2003-2008
Thermoplastic resins
665 (1467)
781 (1722)
3.3
Thermosetting elastomers
104 (230)
120 (264)
2.8
Thermoplastic elastomers
32 (70)
38 (83)
3.5
Polymer optical fibre
7 (15)
9 (20)
5.9
808 (1782)
948 (2089)
3.2
Total
Plastics Additives & Compounding May/June 2004
32
applications and have both grown on their own and taken some market share from other materials, both thermoplastic resins and thermosetting elastomers. BCC estimates the total US market for wire and cable TPEs in 2003 to be about 32 million kg (70 million pounds), growing at 3.5% to 38 million kg (83 million pounds) in 2008. Other trends in the market include the use of polymer optical fibre (POF) - a plastic used instead of glass to make a fibre optic conductor. However, BCC points out that it is still a rather small market at this time compared to glass optical fibre. Nevertheless POF is cheaper and easier to install and remove, but its growth was held back by its chief drawback of only being feasible in relatively short lengths. Several new short-length applications, such as in automotive and inside-the-home wiring, are being developed and will eventually produce good growth for POF, from about 7 million kg (15 million pounds) in 2003 to 9 million kg (20 million pounds) in 2008. The U.S. market for polymeric materials used in fabrication of wire and cable is large and has been considered to be a mature one for several years, reports BCC. The company adds that technological changes that are affecting the industry have primarily been in communications, where fibre optics continue to replace copper wire and in plenum wire where special insulation is required to withstand potential high temperatures and toxic combustion products. However, another major trend likely to affect the market is the rapid growth of wireless technology.
ISSN1464-391X/04 © 2004 Elsevier Ltd.All rights reserved.
Wire and cable Lead-free technology US company Teknor Apex has introduced a number of new compounds for the wire and cable industry. According to the company, Apex® 80853F insulation compound has become the first lead stabilizer-free PVC product to achieve Underwriters Laboratories listing for continuous service at 90°C in wet locations in wire designated in the National Electrical Code (NEC) as THWN-2. The company explains that although manufacturers of conventional wire and cable compounds have used lead stabilizers to ensure the retention of electrical properties, the new Apex compound provides insulation so effective that it actually replaces lead-containing formulations. Lead-based heat stabilizers provide PVC polymer with high resistance to thermal degradation, which can compromise electrical performance. Yet while most insulators based on standard leadcontaining PVC compounds are restricted for use only with black formulations and in wire above a certain minimum gauge, the new Apex 80853F compound is claimed to be unrestricted as far as colour or gauge is concerned. Teknor Apex says that it believes that Apex 80853F to be the only no-lead vinyl compound rated for wet-location use at 90°C continuous service available from any supplier, whether merchant or captive compounder. Since the typical THWN application presents the worst-case scenario in that its vinyl insulation is thinnest, the outstanding electrical properties of this new compound make it suitable for a wide range of other uses as well, says the company. THWN-2 wire is nylon-jacketed, vinylinsulated building wire used in industrialequipment applications such as control wires for motors. Other wet-location uses anticipated for the new compound include machine-tool wiring (MTW), appliance wire (AWM), and outdoor flexible cord (STW). Teknor Apex adds that it received the 90°C listing for Apex 80853F from UL only months after the compound was listed for continuous service at 75°C and
Semi-flexible conduits have solved a wire and cabling problem in Chicago, USA. (Photo:Teknor Apex)
105°C in wet and dry locations, respectively.
Semi-flexible conduit Teknor Apex has also taken proven technology in cable compounding and adapted it for semi-flexible conduits to solve another problem facing the wire and cable industry. New technology involving Fireguard® Low-Smoke/Zero Halogen, or LSZH™, compounds is now enabling installers of cable in municipal, public-utility and similar projects to save time and costs by using semi-flexible plastic conduit while eliminating concerns about excessive smoke generation in fires. Under a pending patent applied for jointly by Teknor Apex and cabling system supplier Arnco Corporation, Arnco has used a specially formulated Fireguard LSZH compound to develop Fiber-Guard® LSZH conduit, a coilable product that contains no halogens either in the base polymer or in flame retardant
33
additives. The first application of the new conduit is in an 8km (5 mile) project beneath the city of Chicago in the USA According to Robert Washburn, Arnco's vice president of R&D, unlike metal conduit, which is shipped in standard 3m (10 ft) sections and must be assembled onsite, semi-flexible plastic conduit comes in continuous coils that can be fed through the city substructure with minimal disruption of surrounding components. In addition, he adds that continuous conduit permits the use of new fibre optic cable blowing techniques, which are precluded by the enormous number of joints required in any sizeable installation of metal conduit. The Chicago project involved running cable through the stations and tunnels leading into the city centre on one route of the Chicago Transit Authority (CTA) railway system. CTA requirements call for use of low-smoke/zero-halogen coiled conduit in order to increase the visibility of exit areas in the event of a fire and to
Plastics Additives & Compounding May/June 2004
Wire and cable as telecommunications, data communications, cable television, and electrical utilities."
PVC alternative
Low-Smoke/Zero Halogen compounds have been used to produce semiflexible conduits for installing cables. (Photo:Teknor Apex)
reduce the toxic effects and corrosion caused by acid gases emitted as combustion byproducts. According to Arnco, Fiber-Guard LSZH conduit provides the CTA with the best of both worlds. Most importantly, it helps ensure public safety in the event of a tunnel fire. At the same time, it has contributed to the economical and ontime completion of a project that would otherwise have entailed tedious, labourintensive 'one-stick-at-a-time' assembly. Fireguard® is a Teknor Apex tradename for compounds that meet stringent low-flame, low-smoke requirements for wire and cable insulation and jacketing. While most Fireguard products are PVC-based, Fireguard LSZH compounds are polyolefin-based, completely halogen-free formulations. They were originally developed for insulation and jacketing of copper and fibre optic cable for communications and data transmission. "While Fireguard LSZH compounds have been used successfully in the U.S., our main goal in developing them was to support companies that manufacture in or distribute to Europe, where smoketoxicity restrictions are particularly
stringent," says Donald G. Ouellette, industry manager for Teknor Apex. "To transfer this technology to applications in conduit, we adapted the Fireguard LSZH formulation for use in the process of extruding tubing." The CTA installation is just the first of what Ouellette envisages to be numerous uses of Fireguard LSZH compounds in conduit. "We see possibilities in conduit used by natural gas distributors, cable TV companies, telecommunications providers, and electrical utilities," he says. "Unlike traditional materials used for plastic conduit tubing, Fireguard LSZH compounds do not emit the type of combustion byproducts that have raised concerns about toxicity." The new Fiber-Guard LSZH conduit fits right into what Arnco calls The System. Arnco says that it has created a synergistic approach to the challenges of cable installation. To make installations faster, more precise, and more cost-efficient, the company adds that it has developed a system of standard and custom-built conduit, couplers, cable-placing equipment, pull tapes, chemicals and accessories for use in industries as diverse
Plastics Additives & Compounding May/June 2004
34
GE Advanced Materials has introduced a new family of flexible NORYL® modified-polyphenylene ether (MPPE) resin as an alternative to polyvinyl chloride (PVC), flame-retarded polyethylene (FR-PE), and thermoplastic polyurethane (TPU) in wire-coating applications for the direct-current (DC) cord and plug segments of the consumer electronics industry. The company says that the new products - NORYL WCD910 and NORYL WCP860 resins have passed bending-strength tests by charger manufacturers, address eco-label flame-retardant application concerns, and contain no halogens, such as chlorine, which can break down into dioxins and toxic, highly acidic gasses when burned. The new GE resins are also claimed to offer a lower specific gravity than FR-PE and TPU - weight reductions of 20-30% are achievable - as well as faster extrusion rates for potentially higher productivity and lower systems costs. According to the company, NORYL WCD910 and NORYL WCP860 resins address several important needs of the electronics cord/plug segment. These include the increased use of nonhalogenated compounds particularly in Europe and Asia, as well the need to reduce or eliminate the use of heavy metal pigments. Additionally, there is strong incentive to use polymers that can easily be recycled - both in the plant and at the endof-component life. GE Advanced Materials adds that both materials suppliers and OEMs in these highly competitive segments are extremely interested in opportunities for costeffective environmental solutions beyond those that currently exist. According to the company, the new flexible NORYL resin grades have been designed to help meet these and other changing needs of the electronics, electrical, computing, and telecommunications sectors in a number
Wire and cable Crosslinking by electron beam applications, such as telephone wire, aircraft wire, hookup wire, appliance wire, automotive wire, power cable, marine cable, communication cable, fibre optic cable, battery cable and welding cable to resist high temperatures and corrosive diesel, oil and hydraulic fluid. According to E-Beam Services, the process crosslinks wire and cable, in the finished form, without the use of chemicals or other substances that could degrade the quality and integrity of the final product.The crosslinking process does not require the use of additives or heat.The company adds that the process can accommodate a wide range of jacket materials and wall thicknesses without the need for auxiliary processing equipment.This avoids the problems and limitations associated with thermochemical crosslinking. E-Beam Services adds that the crosslinked wire and cable is not dependent on extrusion parameters, because the process takes place off-line and in the solid state.The company says that the high speed continuous crosslinking process yields an accurate, High performance wire and cable products are crosslinked by a high energy e-beam process for better chemical and moisture resistance.
reliable, uniform, dimensionally stable output.The process is said to work with jacketing materials as diverse as compounds
A high energy electron-beam crosslinking process can permit
based on chlorinated polyethylene, chlorosulphonated
wire and cable manufacturers and OEM product designers to
polyethylene, polyethylene, ethylene-vinyl acetate, polyvinyl
achieve good moisture and chemical resistance, according to
chloride, ethylene-tetrafluoroethylene, polyvinylidene fluoride,
US company E-Beam Services.The company says that the high
Neoprene rubber and ethylene-propylene rubber.
performance crosslinking process improves the physical
Contact:
properties of wire and cable products used in single- and dual-
E-Beam Services
wall applications. In addition, it can be used in speciality product
Tel: +1 877 413 2326
of ways. They are non-halogenated, contain no heavy-metal pigments, offer broad thermal performance, and are lighter and more flexible than many competitive thermoplastics. GE Advanced Materials adds that because they have higher flow characteristics, they can process faster for potentially increased productivity and reduced systems costs compared with FR-PE and TPU. NORYL WCD910 and NORYL WCP860 resins are the first in a new line
of MPPE products from GE Advanced Materials specifically developed for wirecoating applications. NORYL WCD910 resin is formulated for use in DC cords, while NORYL WCP860 resin is formulated for use in plug applications. In 2004, GE says that it plans to unveil new halogen-free flame-retardant (VW-1) versions of these materials for applications that require added FR protection. GE Advanced Materials believes that the new flexible NORYL resin grades are also good potential candidates for a variety of
35
consumer electronics applications. These include video tape recorder (VTR) cameras; radio/cassette, portable CD, micro-disk (MD), MP3, and DVD players; video/TV games; and soundsystem components. In the computing area, the new GE products are expected to be used in plug and cord applications for desktop and notebook computers, personal digital assistants (PDAs), faxes, portable personal computers (PPCs), printers, scanners, and digital cameras. In telecommunications,
Plastics Additives & Compounding May/June 2004
Wire and cable GE anticipates the flexible MPPE resins to make inroads into application areas such as mobile phone accessories and cordless phones. According to Elly Burghout, NORYL resin product manager, GE Advanced Materials, NORYL WCD910 and NORYL WCP860 resins are meeting highly specific needs. "The electronics industry needed a tough, eco-sensitive resin technology with excellent insulating properties, broad chemical resistance, and superior processability - and there was a huge void in terms of what was available," Burghout said. "So we determined that our modified PPE offered the best balance of properties, and then tailor-made two new products to meet these needs and more. In the process, we created a totally new family of NORYL resins for wire-coating applications. The initial success of these materials has been excellent and we are currently looking to translate the products into new areas. Automotive is particularly interesting," Burghout added.
Low voltage power cable ExxonMobil Chemical has introduced a new linear low density polyethylene (LLDPE) resin, LL 4004EL, for lowvoltage power cable insulations. The company says that the resin is available throughout the world and provides the cable manufacturer with a balance of crosslinking speed and ease of processing for cost-competitive cable constructions. "Due to optimization of its antioxidants and improved polymer characteristics, this resin has been especially designed for Silane cross-linking technology, where crosslinking speed and processability are key," said Malcolm J. Kaus, ExxonMobil Chemical Company Global PE Products Technology Manager. "We believe these improvements will provide a cost-effective alternative for cable manufacturers." ExxonMobil says that LL 4004EL resin has been field-tested for two years and is suitable for processing in both one-step (Monosil) and two-step (Sioplas) process technology.
Dyneon has expanded its product line of fluoropolymer raw materials for the wire and cable industry.
Plastics Additives & Compounding May/June 2004
36
ExxonMobil Chemical LDPE and LLDPE grades have been used successfully for more than 15 years in wire and cable silane technology. According to the company, continual quality testing, along with controlled shipping logistics, ensures uniform, consistent products. Wire and cable manufacturers will benefit from increased efficiency of their cable production. Dyneon has expanded its product line of fluoropolymer raw materials for the wire and cable industry. The company says that it has added Dyneon™ PVDF to go with its PTFE, FEP, ETFE, PFA and THV™ FP products. The materials are said to have universal chemical resistance and are suitable over a broad range of temperatures. They are used primarily in the automotive, aerospace and chemical industries, for example in sheathing for heating wires in seats, cables for xenon headlights and for lambda sensors in exhaust gas systems. They can also be used for high speed data lines. Contact: Arnco Inc Tel: +1 440 322 1000 Fax: +1 440 322 1001 E-mail: [email protected] Website: www.arncocorp.com Business Communication Co. Inc. Tel: +1 203 853 4266 E-mail: [email protected] Website: www.bccresearch.com Dyneon GmbH Tel: +49 2131 14 2726 Fax: +49 2131 14 3857 E-mail: [email protected] Website: www.dyneon.de ExxonMobil Chemical Company Tel: +1 281 870 6607 Fax: +1 281 870 6353 Website: www.exxonmobilpe.com GE Advanced Materials Tel: +1 413 448 6959 (Americas & Asia) E-mail: [email protected] Tel: +31 164 29 20 97 (Europe) E-mail: [email protected] Website: www.geplastics.com Teknor Apex Tel: +1 401 725 8000 Fax: +1 401 729 0166 E-mail: [email protected] Website: www.teknorapex.com