Development of a Tough & Flexible Halogen Free Dual Layer Wire Insulation System for Electronics Applications
Development of a Tough & Flexible Halogen Free Dual Layer Wire Insulation System for Electronics Applications Akshay H. Trivedi, Ph.D Sr. R&D Engineer...
Development of a Tough & Flexible Halogen Free Dual Layer Wire Insulation System for Electronics Applications Akshay H. Trivedi, Ph.D Sr. R&D Engineer
Judd Wire, Inc.
Judd Wire Inc. is an ISO-9001 and QS 9000 registered firm and a member of the Sumitomo Electric Industries group of companies
Outline • Judd Wire Overview • Background on Halogen Free Materials • Trends in Automotive and Electronics Industries • Requirements for Electronics wires • Features of Dual Layer HF Insulation System • Potential Commercial Applications • Summary and Conclusions 12/12/02
Judd Wire Inc. is an ISO-9001 and QS 9000 registered firm and a member of the Sumitomo Electric Industries group of companies
Judd Wire Inc. is an ISO-9001 and QS 9000 registered firm and a member of the Sumitomo Electric Industries group of companies
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Why and How ?? A Judd Wire Perspective • Trends in Automotive Industry – ISO 14001 - Environmental Management System • Life Cycle Assessment – Material Recyclability – Product End-of-Life (Land-fill, Incineration)
– Environmental Performance and Labeling
• Tier 1 “Environmental, Health and Safety” Specifications – “Reportable”, “Restricted”, or “Prohibited” Components – Requirements for Suppliers like Judd Wire
12/12/02
Judd Wire Inc. is an ISO-9001 and QS 9000 registered firm and a member of the Sumitomo Electric Industries group of companies
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Why and How ?? A Judd Wire Perspective • ISO 14001 Timeline – Ford & GM • Tier 1 Suppliers must have all manufacturing sites by the end of 2002
– Daimler Chrysler • Has requirements in place, timing unknown.
• Cost vs. Performance
12/12/02
Judd Wire Inc. is an ISO-9001 and QS 9000 registered firm and a member of the Sumitomo Electric Industries group of companies
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Why and How ?? A Judd Wire Perspective • Trends in Electronics Industry – Driving Forces- Europe and Asia vs. N. America – Performance of Halogenated and Leaded Materials – Cost still a deciding factor !!!
12/12/02
Judd Wire Inc. is an ISO-9001 and QS 9000 registered firm and a member of the Sumitomo Electric Industries group of companies
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Requirements of Wires for Electronic Applications • • • • • • • 12/12/02
UL Standard Flame Resistant (VW-1) Tensile Strength ≥ 10.3 MPa Elongation ≥ 100% Heat Deformation at 136oC (105oC Rating) Heat Resistance 7d @ 136oC, 90 d @ 113oC (105oC Rating) Dielectric Withstand Voltage Low Temperature (1 hr. @ -30oC) Judd Wire Inc. is an ISO-9001 and QS 9000 registered firm and a member of the Sumitomo Electric Industries group of companies
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Comparison of Halogen and Non-Halogen Based Flame Retardants Oxygen Index (% O2)
60 VW-1 pass
50 40
VW-1 pass
30 Non Non Halogen Halogen based based FR FR
20 10
Bromine Bromine Based Based FR FR
0 0
20
40
60
80
Flame Retardant Ratio in Compound (wt % ) 12/12/02
Judd Wire Inc. is an ISO-9001 and QS 9000 registered firm and a member of the Sumitomo Electric Industries group of companies
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Physical Property of Halogen Free Insulation 60
25 VW-1 pass
20
40
15
UL Requirement
30
10
20 10
5
0
0 0
20
35
50
60
70
75
Tensile Strength (M Pa)
Oxygen Index (%O2)
50
80
Zero Halogen Ratio in Compound (wt%)
12/12/02
NOTE: Data developed on 20 AWG / 0.27 - 0.80mmt
Judd Wire Inc. is an ISO-9001 and QS 9000 registered firm and a member of the Sumitomo Electric Industries group of companies
Judd Wire Inc. is an ISO-9001 and QS 9000 registered firm and a member of the Sumitomo Electric Industries group of companies
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Key Customer Requirements • • • • •
12/12/02
High cut-through performance VW-1 and IEEE-383 Vertical Tray Flame Rated UL and CSA Certified (150% elongation, 1800 PSI tensile strength) Flexibility
Judd Wire Inc. is an ISO-9001 and QS 9000 registered firm and a member of the Sumitomo Electric Industries group of companies
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Goals of Current Investigation • Develop a Halogen Free Insulation System – Enhance Mechanical Properties – Improve Flexibility – Meet Stringent Flame Standards i.e. VW-1 and IEEE-383
12/12/02
Judd Wire Inc. is an ISO-9001 and QS 9000 registered firm and a member of the Sumitomo Electric Industries group of companies
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Cross-Section of Dual Layer HF Insulation
Tinned Copper Conductor 10 AWG 105/30 T Outer Layer Thickness = 0.10 - 0.25 mm
12/12/02
Inner Layer HF insulation (XLPO) Thickness = 0.685 mm
Judd Wire Inc. is an ISO-9001 and QS 9000 registered firm and a member of the Sumitomo Electric Industries group of companies
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Cu t th r u Re s is tan ce (Kg f.)
Comparison of Various Products with Competitors 45.0 40.0
38.9
35.0 30.0 25.0 20.0 15.0 10.0 5.0 0.0
25C
21.3
60C
16.1 11.6
11.8 4.3
10 105/30T 150C (UL3398)
10.2 0.9
90C
0.5
10 37/26T 105C HF (UL 3385)
10 105/30T PVC/Nylon THHN
Note: UL 3398 (Hal.) and UL 3385(HF) data are on a single insulated product with conductor. 12/12/02
Judd Wire Inc. is an ISO-9001 and QS 9000 registered firm and a member of the Sumitomo Electric Industries group of companies
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Cut through Resistance (Kg.)
Cut through Resistance of Various Jacket Materials 40.0 35.0 30.0 25.0 20.0 15.0 10.0 5.0 0.0
25C 60C 90C
PA1
PA2
PA3
PA4
TPA
TPE
HDPE Control
Type of Jacket Material
12/12/02
Judd Wire Inc. is an ISO-9001 and QS 9000 registered firm and a member of the Sumitomo Electric Industries group of companies
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Comparison of Various Products with Competitors C u t th r u Re s is tan ce (Kg f.)
Judd Wire Inc. is an ISO-9001 and QS 9000 registered firm and a member of the Sumitomo Electric Industries group of companies
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Factors Affecting Cut through Resistance and VW-1 Flame • Ratio of Inner to Outer Insulating Layer (Jacket) • Type of Outer Insulating Layer – Toughness – Inherent Flame Retardency
• Flame Retardency of Inner Insulating Layer
12/12/02
Judd Wire Inc. is an ISO-9001 and QS 9000 registered firm and a member of the Sumitomo Electric Industries group of companies
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Features of Dual Layer HF Insulation System • • • • • •
UL & CSA Certified Excellent Flexibility Improved Abrasion Resistance High Cut-through Resistance 105°C Temperature Rating UL VW-1 & IEEE 383 Vertical Tray Flame Rating • UL1685 Limited Smoke 12/12/02
Judd Wire Inc. is an ISO-9001 and QS 9000 registered firm and a member of the Sumitomo Electric Industries group of companies
Secondary Power Supplies Appliances Fire Warning Systems Security Alarms Ventilation Systems Escalators Operation and Maintenance Equipment Judd Wire Inc. is an ISO-9001 and QS 9000 registered firm and a member of the Sumitomo Electric Industries group of companies
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Summary and Conclusions • Unique Halogen Free Dual Layer Insulated System with Superior Mechanical Properties • UL AWM 3660, 105oC, CSA AWM I A/B, VW-1, IEEE-383, UL 1685 (Low Smoke) • Applications Development work underway for Automotive Customers • Balance of cost and performance - a big challenge!! 12/12/02
Judd Wire Inc. is an ISO-9001 and QS 9000 registered firm and a member of the Sumitomo Electric Industries group of companies
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Thank You !
12/12/02
Judd Wire Inc. is an ISO-9001 and QS 9000 registered firm and a member of the Sumitomo Electric Industries group of companies