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...
Author: Elwin Hodge
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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

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Background: Sources of Concern • Halogens: – F: Fluoropolymers – Cl: PVC, CPE, Flame Retardants – Br: Flame Retardants

• Lead Compounds – Stabilizer for PVC, CPE

• Cadmium – Copper Alloys, Pigments for Color Concentrates

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

3

Why Why halogen halogen free? free? Environmentally safe environmental harm

No acid gas emission HCl,HBr

Halogen free dioxin Low smoke emission 12/12/02

Low combustion gas toxicity

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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Halogen Free Technology • Halogen Free – Replacement of halogenated polymers or halogenated flame retardants – Typically: Metal hydroxides, phosphorus compounds, melamine compounds

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

5

Insulation Materials for Electronic Wires (Current Products) Temp. Rating 80oC o

105 C o

125 C o

150 C o

200 C 12/12/02

Insulation Material PVC PVC or XLPVC Crosslinked flame retarded PE Crosslinked flame retarded PE

Halogen Cl

Cl or Br

Silicone Rubber Fluorinated Polymer Fluorinated Polymer

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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Insulation Materials for Environmentally Friendly Electronic Wires Temp. Rating 80oC 105oC 125oC o

150 C o

200 C

12/12/02

Insulation Material

Halogen

Zero Halogen Flame Retarded PE Crosslinked Halogen Free Flame Retarded PE

-

Silicone Rubber Fluorinated Polymer Fluorinated Polymer

F

Judd Wire Inc. is an ISO-9001 and QS 9000 registered firm and a member of the Sumitomo Electric Industries group of companies

7

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

9

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

12

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

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Requirements in Practical Use • • • • • •

12/12/02

Flexibility Cut-through resistance Strippability Abrasion Resistance Volume Resistivity Dielectric Constant

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

18

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

19

Comparison of Various Products with Competitors C u t th r u Re s is tan ce (Kg f.)

45.0

38.9

40.0 35.0 30.0 25.0

25C

21.3

20.0 15.0 10.0 5.0

11.8

11.6 4.3

60C

17.4

16.1 10.2

13.1

90C

0.9 0.5

0.0 10 105/30T 150C (UL3398)

12/12/02

36.5

10 37/26T 105C HF (UL 3385)

10 105/30T 10 105/30T 105C Dual PVC/Nylon THHN Layer HF (UL 3660)

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

21

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

22

Potential Commercial Applications • • • • • • • 12/12/02

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

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