l Electrical & Electronics

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1 l Electrical & Electronics

2 Company overview l Pan-European distribution company since 2002 More than 240 employees 24 offices 30 warehouses Main suppliers SABIC Innovative Plastics TM Headquarters Ultrapolymers Group NV Gerard Mercatorstraat Lommel Belgium Tel +32 (0) Fax +32 (0) info@ultrapolymers.com Electrical & Electronics l 3

3 A spirit of Partnership Ultrapolymers Group was founded in October 2002 in Belgium, to distribute polymers for major polymer producers across several countries in Europe. Since then, the Ultrapolymers Group has grown to become one of the largest Pan-European polymer distributors. With offices and warehouses in most the European countries as well as Turkey and South Africa, Ultrapolymers has established a commercial network with a local presence to serve its customers and suppliers in the best possible way. We offer a comprehensive product portfolio of raw materials covering commodities, engineering plastics, thermoplastic elastomers and synthetic rubbers. We can deliver any quantity from 1 bag to a full truck load. 4 l Electrical & Electronics

4 To be a First In Class distribution organisation for plastic and rubber raw materials, driven by quality of service to our customers. To provide our products and services in a reliable and technically proficient way. To conduct this business ethically, in a spirit of partnership with our suppliers and stewardship with our staff. Electrical & Electronics l 5

5 Ultrapolymers, in partnership with industry leading suppliers, can supply a wide range of materials for electrical & electronic applications in combination with an excellent service and technical support based on years of experience. Ultrapolymers offers the European market high end materials produced by the most experienced suppliers. Within the E&E segment we have a portfolio of products with excellent flame retardant, electrical resistant and chemical resistant materials that can serve for developing new E&E applications. 6 l Electrical & Electronics

6 Aquafil Engineering Plastics creating value for the customer With a focus on continuous improvement and meeting the new market standards set by the E&E industry, Aquafil is a strong player in the E&E market. Offering polyamide materials with various levels of flame retardancy and electrical insulation properties is the first step of Aquafil s approach to the E&E segment. In addition, Aquafil also provides custom compounds to meet the specific needs of every individual customer research projects, Aquafil strives to be innovative through finding new and better polymers for the future. Aquafil Electrical & Electronics l 7

7 Aquamid 6 & 66 As a professional and flexible compounding organisation, Aquafil supplies high quality polyamide 6 and 66 materials with the following properties: General purposes Fast cycle Improved toughness Glass fibre reinforced from 10% up to 50% Glass microspheres filled Low warpage Good aesthetics UV, heat and hydrolysis stabilised compounds High fluidity à Thin wall thickness applications Flame retardant polyamide Because the E&E market requires plastics with a more outstanding performance, Aquafil offers customers PA 6 & 66 materials with not only good mechanical, but also excellent flame retardancy and electrical insulation properties. V0 unfilled halogen free V2 unfilled with halogen V0 reinforced with polymeric halogen V0 unfilled halogen free (PA 66 only) V0 unfilled halogen free with red phosphorus V0 reinforced halogen and phosphorus free (patented) APPLICATIONS Electrical insulation components Electrical plugs Fans MCB/MCCB Transformers Contactors Switch gear Rotating switches Switches and connectors Thanks to the nano composite technology their red phosphorus products contain a lower quantity of red phosphorus than the previous version, which results in: 1. Lower phosphine emissions 2. Competitive prices 8 l Electrical & Electronics Aquafil

8 Aquafil Electrical & Electronics l 9

9 Vydyne polyamide 66 is one of the most costeffective engineering thermoplastics available to you and your designers. You can use Vydyne with confidence in your electrical and electronic applications, including connectors, relays, switches, plugs, housings, cables, buttons and knobs, input/output ports, insulators, face plates, transformers, terminal blocks, and coil bobbins. 10 l Electrical & Electronics Ascend

10 Vydyne resins are highly crystalline and exhibit a high melting point (500 F / 260 C). Due to these attributes, your PA66 products will be strong, tough, abrasion-resistant, and resistant to chemicals at elevated temperatures. If made from Vydyne, your components will withstand abuse during the assembly process, including through-hole soldering, and they will survive the difficult environments of your end-users. Ascend s expert applications development specialists help your engineers and designers develop innovative and cost-effective nylon solutions to satisfy your design criteria. High Crystallinity Flow properties are outstanding and the inherent fast crystallisation rates provide Vydyne nylon with the ability to fill complex, thin wall parts as well as reduce injection moulding cycle times. Long-term Heat Resistance The long-term, heat-aging resistance of Vydyne nylon (measured on the Relative Temperature Index) is comparable to the long-term heat resistance of polybutylene terephthalate (PBT). This means that Vydyne parts can withstand long-term exposure to elevated temperatures. Electrical Insulating Properties Excellent dielectric strength and comparative tracking index are combined with an inherent V2 flame rating, which can be reduced to V0. This makes Vydyne nylon the right choice for low-voltage circuit applications. Ascend Electrical & Electronics l 11

11 The high quality and superior consistency of Vydyne nylon products are the results of Ascend Performance Material s integrated approach to manufacturing PA66. When you use Vydyne compounds and resins, you can expect every order to deliver efficient solutions to boost your productivity and help you deliver better injection moulded and extruded end products. 21SPC 21SPF/21SPG1 20NSP/20NSP1 22HSP lubricated exceptional mould release and flow standard product for cable tie lubricated medium nucleation standard product for cable tie high nucleation heat resistance lubricated exceptional mould release and flow When producing products that have to serve in the electrical and electronics market, you might need plastics with improved ignition resistance and better dielectrical properties. Ascend Performance Material brings specialised resins to the market that help customers in producing excellent products with the desired characteristics. ECO-315 no glass fibres halogen & phosphorus free 94-V0 M344 no glass fibers contains halogen & phosphorus 94-V0 & 94-5VA % glass fibers contains halogen & phosphorus 94-V0 & 94-5VA Key applications FLAME RETARDANT None Mixed Yes (mostly non-hal) Battery seals Switches Wall plates Power cords Cable glands Terminal blocks GLASS FIBER None Mixed Lighting Small appliances Connectors Solar PV Motors Bobbins Office equipment Miscellaneous EE Circuit breakers Yes 12 l Electrical & Electronics Ascend

12 ECO-366: NEW Non-Hal FR Homopolymer Nylon 6,6 ECO-366 is a non-halogenated Nylon 6,6 homopolymer. It is formulated for electrical and electronics applications requiring excellent flow characteristics, and has a UL V-0 flame rating at 0.4mm thickness. ECO-366: Unique Combination of Properties High melting point High temperature use for soldering and other applications High stiffness Expected high RTI rating High flow for thin-walled or intricate parts No plate out Applications: Electrical connectors, terminal blocks, housings, clips, clamps, fasteners, cable ties, industrial parts,... Application Profiles Application Requirements Products Terminal blocks Connectors Unattended appliances Non-hal, UL-94 V-0 at 0.4 = 0.75 mm UL-195 PLC 4, PLC 3 PLC 3 (>250V) RTI of 105 C for electrical, strength RTI of 105 C for electrical, strength Good flow, stiffness, low dielectric strength Non-hal, UL-94 V-0 at 0.4 = 0.75 mm PLC 4, PLC 3 RTI of 100 C for electrical, strength GWFI > 850 C, GWTI > 0.75 mm GWFI > 850 C, GWTI > 0.75 mm Ball pressure temp > 125 C ECO-366 ECO-315 ECO-366 ECO-315 Connectors Solar Cable glands Non-hal, UL-94 V-0 at 0.4 = 0.75 mm PV Standard EN Ball pressure test > 200 C Inclined plane tracking (IPT) > 1,000 volts f1 rating Good low temperature impact strength UL 1660, UL 514B RTI electrical > 90 C RTI strength > 90 C RTI impact > 50 C ECO-366 ECO-315 ECO-315 Ascend Electrical & Electronics l 13

13 At every moment of every day, LyondellBasell s products help enhance the quality of life for people around the world. LyondellBasell don t just sell advanced polyolefins and polypropylene resins, they deliver competitive advantages to their customers in the E&E / appliance markets. 14 l Electrical & Electronics Lyondellbasell

14 LyondellBasell is the leading polyolefin producer in the world. In terms of supplying to the electrical and electronics market, this means their products are always the best solution for meeting their customers needs. Leading producers of electrical and electronical products such as Bosch, Siemens, Miele, Husqvarna,etc. all choose LyondellBasell s products as base materials due to their high performance and cost-saving characteristics. Within the wide segment of E&E applications LyondellBasell and Ultrapolymers offer the PB-1, Softell, Clyrell and Hifax materials. Special mention must be made of the Hostacom materials which are glass fibre-reinforced, mineral filled and unfilled coloured TPOs and TPEs, often used by customers in electrical applications. LyondellBasell also offers a further improved portfolio of Advanced Polyolefin (APO) materials. These are custom PE/PP compounds for very specific needs in the market. Highly chemically inert Most products approved by the US Underwriters Laboratories (UL) Good long-term heat resistance High performance/total costs effectiveness High melting temperature (approx. 165ºC) and high degree of crystallinity Superior recyclability of polyolefin-based products in compliance with the European directive regarding waste electrical and electronic equipment (WEEE). Long-term heat aging by using reinforcement materials Pump from washing machine Lyondellbasell Electrical & Electronics l 15

15 Based on more than 50 years of experience in the plastics market, Ravago is your valuable partner in the market. As a leading worldwide plastic distribution and compounding company, Ravago is able to serve its customers in the E&E market with a variety of materials of excellent prime and industrial quality. 16 l Electrical & Electronics Ravago

16 Sicoran SAN Industrial quality & Prime FR-grades Sicoflex ABS Prime & Industrial quality Polyfast ASA Prime Mablex PC/ABS Prime & Industrial quality Sicoklar PC Prime & Industrial quality Sicoblend PA/ABS Prime & Industrial quality Sicoter PBT/PPO Industrial quality Ravamid PA Industrial quality & Prime FR-grades The illustrated grade range offers a broad variety of grades that are widely used in markets such as E&E. With more than 50 years experience in the plastics market, Ravago is your valuable partner in this market. Through the years Ravago has developed long term relationships with industry leading customers who profit from the benefits that Ravago offers in terms of materials and services. The outstanding Ravago portfolio of engineering resins is a high value package for the electrical and electronics market. With the wide range of possibilities, there is almost always a plastic material that can serve to produce your E&E end product. All the illustrated brands are well known materials due to excellent mechanical properties and improved ignition and heat resistance. Flame retardant materials (V2,V0) Product design support Custom compounds Colour matching Product design support Own test lab facilities More than 23 grades listed with minimum V2 flame retardant level. Ravago Electrical & Electronics l 17

17 Styrolution plastics whenever extraordinary properties are required Plastics used in the electrical and electronics sectors are required to comply with a long list of physical attributes. They have to be dimensionally stable, weather-resistant, impact-resistant, scratch-proof and anti-electrostatic while still adhering to strict aesthetic criteria, without making any concessions in terms of their processability. 18 l Electrical & Electronics Styrolution

18 Luran Luran S/SC Styrolution PS Styroflex / Styrolux Terblend N Terluran Novodur Terlux NAS Zylar SAN, AMSAN ASA, ASA/PC GPPS, HIPS SBC ABS + PA ABS, HH ABS ABS, HH ABS MABS SMMA MBS When it comes to the electrical and electronics industry, Styrolution recognizes that no sector comes close in terms of rapid pace and its high standards in terms of quality, delivery and service. They understand what it takes for customers to stay competitive in this tough sector. With a strong customeroriented industry-specific approach, and by leveraging their global presence, Styrolution can develop optimized solutions for our customers. These are the reasons why Styrolution is one of the leading suppliers in the electrical and electronics industry. Materials from their advanced and broad styrenics portfolio can be applied across many end-products, including computers, printers, monitors and home entertainment. The key benefits of using styrenics include low specific gravity, low moisture absorption and a lower processing temperature, which can help make transportation and production more efficient. KEY APPLICATIONS PCs and monitors Printers and scanners Game consoles Audio/video/photo devices Small kitchen appliances, such as blenders Cell phones and other portable devices Electric shavers Antenna and communication systems GPS devices Plugs and switches Battery housings All UL listed materials for this supplier can be found via the QR-code on the right. We do not provide a direct link to the related listed materials and advise to fill in the search query in the UL directory. Styrolution Electrical & Electronics l 19

19 Helping manufacturers to achieve an optimum balance of performance, productivity and quality. SABIC Innovative Plastics is a well-established supplier of a wide range of high performance engineering thermoplastic resins to the electrotechnical industry. 20 l Electrical & Electronics Sabic IP

20 SABIC Innovative Plastics TM SABIC Innovative Plastics helps to realise its materials environmental as well as functional adaptibility in meeting tomorrow s needs. Cutting-edge material solutions As electronics continue to advance, global advancements in technology are key to growth in this industry. At the same time, differentiation in design and style is essential to driving sales of individual products. As a premier supplier of thermoplastic resins for the industry, SABIC Innovative Plastics recognises this and shares this dual commitment to consistent quality and cutting-edge innovation. Their broad portfolio of high-performance materials and their expertise have contributed to the development of many current portable electronic device designs, and they continue to create solutions for critical functionality in this segment - from thermal management to shielding. Combining excellent mechanical properties and versatile colorability, SABIC Innovative Plastics thermoplastic technology can help make products more durable and reliant, lighter, and visually unique. Sabic IP Electrical & Electronics l 21

21 22 l Electrical & Electronics Sabic IP

22 SABIC Innovative Plastics TM Brand Polymer Properties Electrical engineering Typical material properties and market overview Cycolac ABS resin Ease of moulding Surface quality Thermal stability Impact resistance Wide range of colours Enclosures, housings and covers, alarm systems switches, plugs, connectors. Cycoloy PC/ABS thermoplastic alloys Ease of moulding Excellent flow Low temperature impact UV stability Flame retardancy Enclosures, battery housings, junction boxes, kwh meter housings, switches, plugs, sockets, cable channel, corrugated pipes Geloy PC/ASA UV stability Property retention after weathering Ease of processing Flame retardant 125 C BPT Wall switches, plugs & sockets, enclosures alarm systems Lexan Noryl Noryl GTX Valox Xenoy Geloy Starflam Stat-Kon Polycarbonate resin Modified PPO resin Modified POP alloys Thermoplastic polyester resin Thermoplastic alloys PC/ASA Thermoplastic alloys PA6 & PA6.6 resin Electrically active compounds Transparency High impact Dimensional stability Temperature resistance Flame retardancy Electrical properties Dimensional stability Hydrolysis resistance Temperature resistance Low water absorption Flame retardancy Chemical resistance Temperature resistance Dimensional stability Inherent flame retardancy Platable vacuum metalisable High strength/stiffness up to high temp. Excellent dielectric properties Excellent electrical properties Chemical resistance Temperature resistance Flame retardancy Fast moulding High impact resistance Chemical resistance Dimensional stability UV stability Ease of moulding Excellent flow Weatherability performance UV stability Impact Excellent electrical properties Mechanical properties Flame retardancy Chemical resistance Electrostatic dissipation Static protection Protection from sparking Electrical conductivity Motor housings, relay separators, connectors, fuse boxes, switches, plugs, sockets, circuit breakers, transformers, KWh meter housings, corrugated pipes KWh meter housings, conduits, connectors, ignition coils, bobbins, yokes, switches, plugs, sockets, components for junction boxes, temperature controllers, enclosures, wire coating, busbars, rigid pipes Internal MCB, MCCB and conductor parts, films; printed circuit boards; switches, plugs,transformers; wire and cable coating (Siltem*). connectors, controls Rotors, connectors, sensors, sockets, plugs, coils; distributor caps, ignition bobbins, terminal blocks, switches, transformers, fuse boxes; housings and enclosures; electric motor end caps Enclosures and housings; Connector boxes. Switches, plugs, cable cannel, enclosures covers, transformer housings MCB, MCCB, contactors, terminal blocks, bobbins, coils, transformers, fuse boxes, fuse-hoders enclosures, housings, e-motor endcaps capacitor Housings, connectors Housings, enclosures, connector box, rotors, rotor-housings Faradex Electrically active compounds EMI-RFI shielding capable Colourable Highest electrical conductivity Housings, enclosures Lubricomp Internally lubricated compounds Wear resistance Noise reduction Reduced friction Enhanced product life cycle Reduced maintenance costs Gears, lever, slider, bobbins, push bottons Thermocomp Fibre and mineral reinforced compounds Tight tolerances High strength & stiffness Housings, enclosures, rotors, connector cable ties, bobbins, coils, clider, lever, covers, transformers Sabic IP Electrical & Electronics l 23

23 We hardly notice it any more, but we are living in the era of plastics. Thanks to their multi-faceted application possibilities, plastics have become an indispensable fixture of modern life. They make tremendous contributions to our quality of life and comfort, to technology and progress, to aesthetics and to our well-being. Plastics are flammable materials, like most natural substances. Fires cause extensive damage to people, property and the environment throughout the world. Important safety aspects in case of fire are precautionary measures that allow early fire detection and firefighting and provide possibilities for escape and evacuation. Moreover, certain safety requirements apply in terms of the fire behaviour of the materials employed and of the articles made of them, always as a function of the actual conditions of use. Such requirements often differ in the various areas of application and cannot be directly compared to each other. However, all of them share the overriding objective of protecting the lives and health of people as well as property and the environment. 24 l Electrical & Electronics BASF

24 Ultramid (PA) Ultramid polyamide (PA) has good electrical insulation properties, useful sliding friction performance, and excellent mechanical strength. It is available in a wide range of flame-retardant grades, and is therefore used in almost every sector of industrial control units, connection technology, electronics as well as in household appliances. Ultrason (PSU, PESU) BASF s Ultrason grades are amorphous thermoplastics with high temperature resistance, which are based on polysulfone (PSU) and polyether sulfone (PESU). Particular features are high dimensional stability and good mechanical properties that are substantially independent of temperature. Ultradur (PBT) Ultradur, the polybutylene terephthalate (PBT) from BASF, has a specific combination of properties making it an ideal material for particular applications in electrical engineering and electronics. It shows not only high stiffness and good thermal resistance but also exceptional dimensional stability and excellent long-term electrical and thermal performance. All UL listed materials for this supplier can be found via the QR-code below. We do not provide a direct link to the related listed materials and advise to fill in the search query in the UL directory. BASF Electrical & Electronics l 25

25 26 l Electrical & Electronics BASF

26 Product UL 94 GWIT 775 GWFI 850 d = 1.5 mm Halogen-free flame retardant Symbol A3K V-2, PA66 Ultramid unreinforced A3U30 V- 0, PA66 FR B3S V-2, PA6 C3U V- 0, PA6/66 FR A3U40G5 V- 0, PA66 GF25 FR A3X2G5 V- 0, PA66 GF25 FR A3XZG5 V- 0, PA66-I GF25 FR A3X2G7 V- 0, PA66 GF35 FR Ultramid reinforced A3X4G7 V -1, PA66 GF35 FR A3X2G10 V- 0, PA66 GF50 FR B3UG4 V-2, PA6 GF20 FR B3U30G6 V-2, PA6 GF30 FR B3UGM210 V- 0, PA6 GF10-M50 FR T KR4365 G5 V- 0, PA6/6T GF25 FR Ultradur unreinforced B 4520 HB, PBT B 4406 V- 0, 0.4 PBT FR B 4406 G2 V- 0, 0.4 PBT GF10 FR B 4406 G4 V- 0, 0.4 PBT GF20 FR Ultradur reinforced B 4406 G6 V- 0, 0.4 PBT GF30 FR B 4441 G5 V- 0, PBT GF25 FR B 4450 G5 LS V- 0, PBT GF25 FR E 2010 V- 0, PES E 3010 V- 0, PES Ultrason S 2010 G6 V -1, PSU GF30 E 2010 G4 V- 0, PES GF20 E 2010 G6 V- 0, PES GF30 BASF Electrical & Electronics l 27

27 Leading compounder of thermoplastic elastomers. The philosophy of Enplast is to be a technically proficient and reliable supplier of plastic materials, who can continually and promptly respond to all product and service requirements of it s customers. Like all Ravago Plastics companies they follow this philosophy, in a spirit of partnership with their suppliers and stewardship with their staff. 28 l Electrical & Electronics Enplast

28 Enplast supplies the global and local TPE market. In the thermoplastic elastomers business division, they produce four main groups of products: TPO, SBS, SEBS and TPV. The philosophy of Enplast is to formulate the compound to the exact requirements of the customer and the application. The aim of bringing customised and high-end materials to the market is a key strength of Enplast in the E&E market. In various applications that require specific insulation properties, Enplast can help you with developing your final product. Moulded-in seals for electrical and electronic enclosures Telephone and mobile telephone parts and housings Lighting and electronic housing gaskets Push buttons and switches for electrical equipment Cable connectors Vibration and sound absorption elements for electric and electronic equipment Cable guides and flexible cable insulations Industrial connector/plug housings Enplast Electrical & Electronics l 29

29 Decades of experience in offering high end PC and PC/ABS materials. In the future, there is expected to be an even higher demand in the E&E market for advanced and composite materials that are environmentally friendly and contribute to low use of resources, weight reductions, energy savings and high-performance that fulfill requirements for safety and security. 30 l Electrical & Electronics Teijin

30 Panlite (Polycarbonate) General Polycarbonate Wide range of MI (Molecular weight) Water clear transparency Flame retardant grade Halogen / Non halogen UV resistance Reinforced grade Wide range of modulus Glass fibre reinforced Carbon fibre reinforced Flame retardant grade Low anisotropy / isotropic grade Light Diffusion grade Wide range of diffusion UL V-0 material is available. Polycarbonate/Polyester blend High impact strength at low temperature Improved chemical resistance Panlite Standard General purpose UV resistance Profile Extrusion L-1250# / L-1225# / L-1225LM L-1250Z / L-1225Z / L-1225ZL L-1250ZW V-2 LV-2225 / LV-2250 Flame retardant Transparent Opaque V-0 V-0 MN-4000 Series MN-3600 H Glass fibre FR V-0 GN-Series 5V GV-3400 series Reinforced Dimensional Stability G(N)- 3000H Series Carbon fibre Standard EMI Shield B(N)- Series E(N)-Series Light diffusion ML-Series Special grade Light Reflection Heat Conductive LD Series H- Series PC/PEst PC/PET PC/PBT AM-9000 / GM-9000 Series AM-8000 / GM-8000 Series Blend Impact modified Standard AM-1800 / AM-1300 Chemical Resistance Opaque Transparent PC/PEst Blend AM-1500 Teijin Electrical & Electronics l 31

31 Multilon (PC/ABS blend) Standard grade Wide range of heat resistance. Good impact strength Flame retardant grade Non Bromine FR grade High level flame retardant, 5VA / 5VB, grade is available Reinforced grade Various type of reinforced grade is available. Plating grade Shows good adhesion. Multilon High Heat Medium Heat T-3714 / T-2810R T-3011 / T-2830R Standard High Impact Metal Plating T-2711J / T-2850R MK-1000A NonFR Anti Static T-3615Q Reinforced Glass Fibre Other fillers R-2000 series T- 2710F Standard Standard Reinforced TN-3000V/ TN-3714V RN-Series FR Housing Standard High Rigidity TN-7000 Series TN-7000F Series Chassis Dimension stability DN Series 32 l Electrical & Electronics Teijin

32 Teijin Electrical & Electronics l 33

33 Flammability & Electrical testing As a representative plastic distribution company supplying into many market segments, Ultrapolymers can not only deliver high quality materials, but also an advanced technical support. Together with the customer we search for the best solution. Understanding the needs and the behaviour of plastic materials in the electrical and electronics market is very important in order to be successful. With many years of experience and highly trained technical staff we can be a valuable partner for our customers. The following tests are standard test methods that are frequently applied in the E&E market. As it is our aim to keep customers as informed as possible, we hereby present an overview of all the different tests that can be used to analyse the behaviour of plastics then they are exposed to a heated, electrical, chemical or stressed environment. 34 l Electrical & Electronics Flammability & Electrical testing

34 UL 94 Testing. Tests for Flammability of Plastic Materials UL 94 Flammability Standard The UL 94 flammability standard by Underwriters Laboratories (UL) is a standard by which plastic materials can be classified with respect to their ability to withstand combustion. The rating of flammability given to a plastic material depends upon the response of the material to heat and flame under controlled laboratory conditions. The test results will give a good indication of the material s acceptability with respect to flammability for a particular application. The behaviour to heat and flame of a thermoplastic depends on many factors such as the size, form, and end-use of the product, but also elements in the final application such as ease of ignition, burning rate, flame spread, fuel addition, intensity of burning, will affect the combustion response of the material. The UL 94 standard consists of three test methods the Horizontal Burning Test the 20 MM Vertical Burning Test the 500 MW Vertical Burning Test H Horizontal Burning Test To perform the UL94 HB test, specimen bars are used with the following properties: length 125 mm (5 in) by 13 mm width (0.5 in) by thickness typically 1.5 mm (1/16 in) or 3.0 mm (1/8 in) or 6.0 mm (1/4 in). Three specimens of each thickness are tested after conditioning for 48 hours at 23 degrees C and 50% RH. Each specimen is mounted with its long axis horizontal and its short axis at a 45 degree angle. Each specimen is marked with two lines, 25 mm and 100 mm from one end of the specimen. Each specimen is supported at one end such that its lower edge is 10 mm above a piece of wire gauze. A 20 mm high blue bunsen burner flame is applied to the free end of the specimen for 30 second and then removed. If the specimen continues to burn after the removal of the test flame, the time for the flame front to travel between the two gauge marks is measured and the burning rate calculated in millimeters per minute. The specimens may: not have a burn rate exceeding 40 mm per minute over a 75 mm span for specimens having a thickness of 3.0 mm to 13 mm OR not have a burn rate exceeding 75 mm per minute over a 75 mm span for specimens having a thickness less than 3.0 mm, OR cease to burn before the flame reaches the 100 mm mark. 100 ± 1 Specimen 25 ± 1 approx. 6 Test flame Burner Support Wire gauze approx. 45 Fig UL 94 HB (or DIN IEC ) Flammability testing & Electrical Electrical & Electronics l 35

35 V Vertical Burning Test The UL94 vertical burning test is a more aggressive variant to the 94HB test. The 20mm-VB test method is only applied on specimen samples that meet the following measurements: 125 mm in length, 13 mm in width minimum thickness at which the rating is desired, typically 0.8 mm or 1.57 mm. The plastic sample is placed in a vertical position with a 20-mm-high blue flame applied to the lower edge of the clamped specimen. The flame is held against the lower edge of the specimen for 10 seconds and then withdrawn. When the specimen stops burning, the flame is reapplied for another 10 seconds and then removed again. In general this test is applied to 5 samples. Specimen Test flame 20 ± 2 10± 1 Burner Support 300 ± 10 Cotton ca. 50 max. 6 Fig UL 94 V (or DIN IEC ) TABLE 1: Test critteria according to UL 94 Horizontal Burning Test (UL 94 HB), flame: 50W Specimen thickness Burning rate Class Flame extinguishes before 100-mm mark - HB mm 40mm/min HB < 3mm 75mm/min HB Vertical Burning Test (UL 94 V), flame: 50W V-0 V-1 V-2 Afterflame time for each individual flaming 10s 30s 30s Total afterflame time for any condition set (10 flamings) 50s 250s 250s Afterflame plus afterglow time for each individual specimen after 2nd flaming 30s 60s 60s Afterflame or afterglow of any specimen up to the holding clamp no no no Cotton indicator ignited by flaming drops no no yes Vertical Burning Test (UL 94 5V), flame: 500W; only materials that fulfill at least V-1 5VA 5VB Afterflame plus afterglow time after 5th flaming, flame application for each specimen 10s 10s Cotton indicator ignited by flaming drops no no Complete burning no no Burn-through (hole) of any plaque specimen no yes < 3mm 75mm/min HB 36 l Electrical & Electronics Flammability & Electrical testing

36 SURFACE BURN VERTICAL BURN HORIZONTAL BURN Doesn t ignite under hotter flame UL 94 5VA UL 94 5VB Self extinguishing UL 94 V-0 (best) UL 94 V-1 (good) UL 94 V-2 (drips) Slow burn rating Takes more than 3 min. to burn 4 inches Fig DIN IEC UL 746A. Testing for ignition and electrical properties The electrical ignition tests measures the ignition resistance of the plastic to electrical ignition sources. The material s resistance to ignition and surface tracking characteristics is described in UL 746A, which is similar to the test procedures described in IEC 60112, and The following electrical ignition tests all conform to UL 746A. Hot Wire Ignition Test ( HWI ) This is a test where an electrically heated resistance wire is wound around a horizontally arranged bar specimen. By doing this, you simulate the overheating of wires which can be an ignition source. Events like this can occur in electrical applications such as a transformer. Components can become abnormally warm caused by the malfunctioning of the device. This may cause the ignition of the material. Depending on how fast or slow the specimen ignites (0 120 seconds), ignition categories PLC 0 to 5. Winded wire (5 turns) Ignition time (s) PLC-Class t > < t < < t < < t < < t < 15 4 Specimen ( mm) 60 < t < 7 5 Fig DIN IEC 60829; A,B Flammability testing & Electrical Electrical & Electronics l 37

37 High Current Arc Ignition Test (HAI) The High-current arc ignition test is the number of arc rupture exposures (standardized to the electrode type and shape and electric circuit) that are needed to ignite the material when they are applied at a standard rate on the surface of the specimen. Movable electrode Arc Number of arcs Assigned PLC Fixed electrode n > Specimen 60 < n < < n < < n < < n < 15 4 U = 250V AC l = max A n = 40 arcs/min Fig High current arc ignition test (HAI) according to UL 746 A, section 32 HAI range mean number of arcs assigned PLC assigned 120 and greater 0 60 through through through 29 3 Less than 15 4 The table on the next page shows how the test results of the HAI and the HWI can be combined with the UL94 V-ratings. What we see is that materials with higher flammability requirements must score better in the HAI and HWI test. For example: if the UL 94 V-0 rating has to be met, you need a HWI above PLC 4 and a HAI above PLC l Electrical & Electronics Flammability & Electrical testing

38 Demands on plastics for insulation purposes in E/E applications (acc. to UL 746 C) Example: For UL 94 V-0, the plastic must have an additional HWI above PLC 4 and an HAI above PLC 3. permissible combinations non-permissible combinations HWI UL 94 V-O HWI UL 94 V-1 PLC 0 PLC 1 PLC 2 PLC 3 PLC 4 PLC 5 PLC 0 PLC 1 PLC 2 PLC 3 PLC 4 PLC 5 PLC 0 PLC 0 HAI PLC 1 PLC 2 HAI PLC 1 PLC 2 PLC 3 PLC 3 PLC 4 PLC 4 HWI UL 94 V-2 HWI UL 94 HB PLC 0 PLC 1 PLC 2 PLC 3 PLC 4 PLC 5 PLC 0 PLC 1 PLC 2 PLC 3 PLC 4 PLC 5 PLC 0 PLC 0 HAI PLC 1 PLC 2 HAI PLC 1 PLC 2 PLC 3 PLC 3 PLC 4 PLC 4 Comparative tracking index (CTI) Fig DIN IEC The Comparative tracking index can be defined the following: it is that voltage which causes tracking after 50 drops of 0,1 percent ammonium chloride solution have fallen on the material. This test is done on a specimen of 3 mm thickness, which is considered representative of the material s performance in any thickness. Measurement of current Power supply Vac Resistance Drop applicator NH 4 CI solution A Test specimen ( 3mm) Fig CTI, measuring principle Flammability testing & Electrical Electrical & Electronics l 39

39 CTI range Tracking index (in volts) PLC assigned 600 and greater through through through through Less than The results of the CTI test can also be categorised in a certain class. We can define four categories. Material groups are classified as shown below, according to :2005: CTI classes for materials Class U test /V CTI failure criteria I 600 II 400 < CTI < 600 IIIa 175 < CTI < 400 IIIb 100 < CTI < 175 0,5 A current for 2 sec 2 sec flame formation IEC glow-wire ignition temperature (GWIT) The GWIT is the temperature which is 25 K (30 K between 900 C and 960 C) higher than the maximum temperature of the tip of the glow-wire, which does not cause ignition of a test specimen of a given thickness during three tests. Glow wire loop (max. 960 C) Specimen Trolley IN Wrapping tissue Fig Glow-wire test according to DIN IEC l Electrical & Electronics Flammability & Electrical testing

40 Glow Wire Testing The Glow Wire Test measures the ignition resistance of plastic materials. The setup of this test simulates the conditions that are present when a glow wire (current conductor) makes contact with an insulation material. This situation may be caused by the malfunction of an electrical application. The glow wire test apparatus consists of a loop of a heavy gauge (10-14 AWG) nickel-chromium resistance wire, a thermocouple, and a sample mounting bracket. To perform the test, an electrical current is passed through the nickel-chromium loop. For every test there will be a predefined temperature at which the test will be performed. Then, the specimen is brought into contact with the wire for 30 seconds. The test is passed if after withdrawal, the sample displays no flame or glowing, or if so, it is self-extinguishing after 30 seconds. DIN IEC Glow-wire flammability index (GWFI) The GWFI is the highest test temperature during three tests for a test specimen of a given thickness, at which one of the following conditions is met. Flames (or glowing of the test specimen) extinguish within 30 s after removal of the glow-wire, + no ignition of the wrapping tissue placed underneath the test specimen. No ignition of the test specimen. DIN IEC Arc resistance With the Arc resistance test, you test the formation of a surface-conducting path when subjected to an intermittently occurring arc of high voltage, low current characteristics. The number of seconds that a material resists this will define the PLC category for the test result. This test is done on a specimen of 3 mm thickness, which is considered representative of the material s performance in any thickness. The test is intended to Approximate service conditions in alternating-current circuits operating at high voltage with currents generally limited to less than 0.1 ampere. D495 range Mean time of arc resistance (in Sec) PLC assigned 420 and longer through through through through through through Less than 60 7 ASTM D495 Dielectric strength The dielectric strength of a material is the maximum AC voltage per unit thickness that the material can handle before it breaks down. The test is built up by placing a sample of material between two neoprene disks coated with silicone grease (to prevent flashover). A dielectric potential is placed across the sample. This potential is increased at a specified rate until breakdown occurs. The test is measured in volt/mil (kv/mm), but they also depend on the sample thickness. Therefore, data on different materials are comparable only for equivalent. Flammability testing & Electrical Electrical & Electronics l 41

41 High voltage arc tracking rate This is the rate, in millimeters per minute that a tracking path can be produced on the surface of the material under standardized test conditions. Every time ignition occurs, this will be recorded. This test defines how susceptible an insulating material is to track or form a visible carbonized conducting path over the surface when subjected to highvoltage, low-current arcing. This test is done on a specimen of 3 mm thickness, which is considered representative of the material s performance in any thickness. HVTR range assigned (in mm/min) PLC assigned 0 through through through through Greater than UL94 746A Volume Resistivity Volume resistivity is defined as the resistance of a unit cube of material when applying 500 volts. The test is done for 60 seconds and then the current is measured. The higher the volume resistivity, the more effective a material is for electrically insulating components. IEC Surface Resistivity With the surface resistivity, you measure the electrical resistance between two electrodes on the surface of a plastic specimen. The material is subjected to 500 volts DC for 60 seconds and the current is measured. The surface resistivity is typically expressed in mm 2 or m 2 per square. A remark to this test is that some finite thickness of the specimen is actually carrying the current. This thickness cannot be measured and therefore, the test results are only an approximate measure. IEC Dielectric Constant The dielectric constant is the ratio of the permittivity of a plastic specimen to the permittivity of free space. Insulating materials are used in two very distinct ways: (1) to support and insulate components from each other and ground, and (2) to function as a capacitor dielectric. In the first case, it is desirable to have a low dielectric constant. In the second case, a high dielectric constant allows the capacitor to be physically smaller. It is an expression of the extent to which a material concentrates electric flux, and is the electrical equivalent of relative magnetic permeability. As the dielectric constant increases, the electric flux density increases, if all other factors remain unchanged. This enables objects of a given size, such as sets of metal plates, to hold their electric charge for long periods. IEC Ball pressure test The ball pressure test defines how much a material deforms under a certain pressure when also being exposed to an elevated temperature. The test specimen is a 3 mm thick plate. This plaque of test material is placed in horizontal position and pressed a steel ball of 5mm diameter with a force of 20 N. The test load and the support must be placed in the oven for a time sufficient to ensure that the stabilization is reached the test temperature before testing. This test is performed in an oven at a temperature of 125 C (+/- 2 C).After 1 hour, the steel ball has to be removed from the specimen and it has to be immersed within 10 seconds in cold water to reach approximately room temperature. The material passes the test when the impression caused by the ball which is not more than 2mm IEC l Electrical & Electronics Flammability & Electrical testing

42 Domestic unattended articles FR testing (IEC 60335) The IEC standard defines fire protection in unattended electrical household appliances. In the past years the demands placed on glow wire resistance of the plastics used for insulating or mounting live components have been increased. In-house fire safety is very important. Household appliances may catch fire due to power surges (glowing components), defective components, arcing switching contacts, faulty electrical connections,,... The IEC standard exists in two parts. The first part (IEC ) is the basic standard governing the majority of the general requirements placed on all electrical household appliances. Part two (IEC xx), is more appliance-specific and specifies more into details special features such as whether an appliance is deemed unattended or attended, the definition of the test procedures, tests concerning the improper use as well as distance measures including pollution degree. In part one, paragraph 30.2, test of heat and fire resistance (see figure 1), defines various requirements for insulating plastics. Insulating materials used for live components in unattended appliances whose current exceeds 0.2 A must meet higher demands in glow wire testing. The plastic materials after-flame times have been shortened accordingly. Part 2, paragraph 30.2, defines whether an appliance as defined is to be deemed attended or unattended and whether it uses the relevant components, such as fuseholders, appliance couplers, timers, circuit breakers for equipment, relays, motors and locks. The rule is that appliances with a built-in timer or program controller or appliances operated by remote control are to be deemed unattended, while portable appliances are to be deemed attended. However, there may also be attended and unattended versions within a Part 2 standard, e.g. the microwave with or without timer as specified in IEC Unattended appliances I > 0.2 A Specimen Moulded part Specimen GWFI 850 C GWEPT Moulded part ü ü GWIT 775 C GWEPT 750 C ü Flame time 5 sec. ü Flame time 2 sec. Moulded part + surrounding part Test passed Test passed For all the unattended operating household appliances (switches and connections in washing machines and dishwashers, refrigerators and ovens, electric motors in vacuum systems or exhaust hoods ) through which high currents flow (more than 0.2 A), the highest safety prescriptions are applied as we have to be cautious with these objects. Plastics used in these devices fundamentally have to pass an ignitability test for the material (GWFI) according to DIN IEC at 850 C. On top, to meet all the safety requirements, a glow-wire test on standardized test plaques according to DIN IEC (GWIT at 775 C, maximum flame duration of 5 seconds) can be applied to make the materials subject of even more severe tests. If the materials do not attain these values the finished component can undergo another test, as an alternative, according to DIN IEC (GWEPT, glow wire end product test, at 750 C, but by a stricter regulation of the maximum flame duration of 2 seconds according to IEC/DIN EN ) or one of three other possible tests on the surrounding components. V0 / V1 Needle flame test Shielded connection Test passed Flammability testing & Electrical Electrical & Electronics l 43

43 Notes 44 l Electrical & Electronics

44 Notes Electrical & Electronics l 45

45 Notes 46 l Electrical & Electronics

46 For all your Electrical & Electronics questions, please contact us: Gerard Mercatorstraat Lommel Belgium Tel +32 (0) Fax +32 (0) ultrapolymers.com Disclaimer: The data indicated above are the results of our investigations and correspond to the state-of-the-art. Ultrapolymers Group and affiliated companies can t guarantee the relevance or accuracy of this information and accept no responsibility in this regard. No liability, warranty or guarantee of product performance is created by this document. It is the buyer s responsibility to determine whether Ultrapolymers products are appropriate for Buyer s use and to ensure that Buyer s workplace and disposal practices are in compliance with applicable laws and regulations.