Insulation Compound & Processing Machine

One of our customer has asked for a automotive cable which requires insulation of Low Voltage Electric Wires. The temperature Class is T3 and Exposure to temperature times required are as follows:

Low Temperature 1000 Hrs, - 40°C ± 2°C
Medium Temperature 3000 Hrs, 125°C ± 2°C
High Temperature 240 Hrs, 150°C ± 2°C

Cable Size: 0.22 Sq. mm to 60 Sq. mm
Maximum Outside Diameter: 1.2 mm to 12.9 mm

The customer suggests that continuous vulcanization (CV) process shall be required for this type of cables.
Please give us a guidance for the suitable Insulating compound and the suitable Extrusion Line for this type of cables. At least the sources who can provide the above will also be a great help. Thanks.

Hello again Shekhar,

This is a starting point for you. You will still have to do a lot of legwork.

Option (A) CV Lines (Most Expensive)
As far as the ideal CV (Organo-peroxide bearing) compounds go, I suggest you contact Borealis at www.borealisgroup.com/ which is represented by Borouge Pte Ltd www.borouge.com/ in your part of the world to get their recommendation. See

Borouge (India) Pvt Ltd.
301, VIP Plaza,
Off New Link Road,
Andheri (W),
MUMBAI - 400 053
Tel: +91 22 2674 7700
Fax: +91 22 2674 7710
email: This email address is being protected from spambots. You need JavaScript enabled to view it.

There is also a method of doing this with regular, non-peroxide bearing polyethylene and a peroxide dosing system in the throat of the extruder but remember that the liquid organo-peroxides are corrosive (meaning all stainless steel tubing and tanks), highly flammable and explosive. The organo-peroxides must also be refrigerated.

Kabel- und Lackdrahtfabriken GmbH (Kabel+Draht), now Südkabel GmbH in Germany used to manufacture and sell refrigerated dosing equipment but there is nothing on their web site now. www.suedkabel.de We suggest you contact them if you want to follow this up as they may recommend some new equipment supplier. The equipment however will not be cheap.

CV Equipment
Since your product is for very low voltage automotive applications, you may be able to cover your full cable range with a steam cure slant CV line. We suggest you contact Troester (Germany) at www.troester.de/ and Maillefer Extrusion (Switzerland) at www.mailleferextrusion.com/

For Gravimetric mixing with a standard PE color masterbatch, we suggest you review the iNOEX GmbH Savomat www.inoex.de/en/saveomat/

Option (Moisture Cure Compounds (Less Expensive)
Borealis/ Borouge may also have a moisture cure pre-grafted compound that fits your needs. (Compound 1)

This Compound 1 is gravimetrically mixed with a Borealis purchased catalyst masterbatch (Compound 2 which Borealis manufactures by the accurate mixing a very clean LDPE or LLPE compounded with an organo tin catalyst such as di-butyl tin laureate) and with a standard PE color masterbatch (Compound 3) at a regular PE extrusion line which you probably already have available.

Moisture Cure Equipment
The cable insulation is then cross linked in a steam room, in boiling water or just by leaving it in a normal plant environment for some period of time.
For Gravimetric mixing we suggest you review the iNOEX GmbH Savomat www.inoex.de/en/saveomat/

Option (C) Do It All Yourself (Least Expensive)
Process "a" - The manufacture of a very clean LDPE or LLPE compounded (pre-grafted) with vinyl silane. This first step is done in a mixing extruder and includes accurate mixing with a peroxide initiator and an antioxidant before pelletizing. We will call this compound "A".

Process "b" - The manufacture or purchase of a catalyst masterbatch produced by the accurate mixing a very clean LDPE or LLPE compounded with an organo tin catalyst such as di-butyl tin laureate and then pelletizing. We will call this compound "B".

Process "c" - The accurate mixing of compound "A" with the catalyst masterbatch (Compound "B") and a standard PE color masterbatch by gravimetrics at a regular PE extrusion line which you probably already have available.

Process "d" - The wire or cable insulation is then cross linked in a steam room, in boiling water or just by leaving it in a normal plant environment for some period of time.

I hope this helps you.

Kindest regards,
Peter J. Stewart-Hay
Principal
Stewart-Hay Associates
www.Stewart-Hay.com