NewNew Products
Products

New Chemical Cross-Linked Halogen-Free Insulated Wire
“EcoacePlus Series”

1.

Table 1INTRODUCTION

New halogen-free wire

Halogen-free equipment wires are mainly used in theoffice equipment and home appliances industries, since
they are environment-friendly containing no harmful substances in their insulation. Work is currently under way
not only to reduce the targeted six substances but also tomake a departure from PVC, aimed at the Restriction of
the Use of Certain Hazardous Substances (RoHS) whichis scheduled to come into force in July, 2006, while thedemand for the wires are basically increasing.
Conventional halogen-free electric wires have adopted,
as the base material, flame-resistant cross-linked polyolefin obtained by electron beam irradiation thereby satisfying both heat resistance and vertical flame resistance.
These products, however, has the disadvantage that,when they are used for wiring under high stress, they are
more susceptible to whitening of the surface due to abrasion than PVC. For this reason, use of halogen-free electric wires has been withheld by some customers and fromsome equipment.
Furukawa Electric has recently developed a new chemical cross-linking technology, and has commercialized“EcoacePlus Series” of new halogen-free electric wires forequipment wiring. By adding this product to our lineup,
we plan to strengthen our capability of responding to therequirement of departure from PVC, and simultaneously,
to expand the adoption of halogen-free electric wires.

＜Basic structure＞
Conventional

Chain of resin

Specifications of EcoacePlus Series.

Rated Rated
Conventional Grade nametemp. voltage
150 V
300 V
105℃

2.

600 V

PVC wire

UL 3384
UL 3385
UL 10368UL 3386

UL1007 （80℃, 300 V）
EcoacePlus
UL1061 （105℃, 300 V）-105
UL1015 （105℃, 600 V）

UL 10369

150 V

UL 3619300 V

UL 10368

EcoacePlus UL10272 （80℃, 150 V）-105R
UL1061 （80℃, 300 V）

NEW CHEMICAL CROSS-LINKED
MATERIAL

The cross-linking technology is generally used to prevent
resins from melting at high temperatures, thereby improving the heat resistance. Conventionally cross-linking iseffected through several methods including peroxidecross-linking in which peroxides are added followed byheat treatment; silane cross-linking in which silane couplers are added followed by hydrothermal reaction treatment; and electron beam cross-linking in which electron
beams are irradiated onto the resin, and in all these technologies a cross-linking process has to follow an extrusion process.

＜New cross-linked structure＞
EcoacePlus

Non-halogen ﬂame retardant

A large amount of ﬂame retardant is needed

Special surface coating is applied to the ﬂame retardant surface

Decrease in interactions of resins

Resin is bonded with ﬂame retardant as well as with resin

Susceptible to damages, decrease in strength

Improvements in heat resistance, strength and external damage resistance

Figure 1

Comparison of cross-linking structures of EcoacePlus and conventional wires.

Furukawa Review, No. 30

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New Chemical Cross-Linked Halogen-Free Insulated Wire “EcoacePlus Series”

Using the new cross-linking technology, in contrast,
resins are cross-linked at the time of kneading, and since
the resins are in a moderately cross-linked state after
kneading, it is possible to extrude the resins necessitating
no cross-linking process after molding, and re-molding ispermitted.
Furthermore, halogen-free insulation materials contain alarge amount of flame retardant as well as base resin ofpolyolefin to achieve a high level of flame resistance.
Focusing attention to this fact, we investigated surface
treatment of the flame retardant together with cross-linking of the base resin, and succeeded in significantly
improving the external damage resistance through binding the flame retardant with the base resin.

3.

Pressure welding (EcoacePlus-105R)

FEATURES OF NEW CHEMICALCROSS-LINKED HALOGEN-FREE
INSULATED WIRE “ECOACEPLUS
SERIES”

Based on this technology, the base resin is firmly bondedwith metal hydrate (i.e. flame retardant) to obtain a highdegree of mechanical strength and external damage
resistance. See Photo 1. Meanwhile, it has been confirmed that the new wire provides wire-end workability ofthe same level as conventional heat-resistant PVC electric
wires in terms of pressure welding and crimping --- common wire-end processing methods for equipment electric
wires. See Photo 2.
The main features are summarized below, and Table 2
shows the test results of general physical properties.
· Excellent external damage resistance· Provided with vertical flame resistance· Material recycling is possible· Provided with wire-end workability of the same level as
PVC electric wires· Free from the six substances specified in the RoHS as
well as halogens, phosphorous and antimony· In compliance with UL standard and CSA standard
EcoacePlus-105

Conventional halogen-free wire

Crimping (EcoacePlus-105)
Photo 2

Table 2

Photographs comparing the surface whitening of
EcoacePlus and conventional wires. SEM images(x60).

Test conditions (UL 758)

Tensilestrength

Tensile speed:
500 mm/min
Elongation Gauge length: 25.4 mm

After aging
tensilestrength
Aging
Aging condition:
ratio
charac136℃ x 168 hr
teristics After aging
elongation
ratio

EcoacePlus EcoacePlus-105-105R
11.7 MPa30.0 MPa

201%

185%

108%

101%

70%

60%

High-temperaturewinding

After winding 6 turns at
No cracks
136℃ x 1 hr
found on
Mandrel diameter:
the surface
self-diameter x 2

No cracks
found onthe surface

Low-temperaturewinding

Winding 6 turns at
No cracks-10℃ x 4 hr
found on
Mandrel diameter:
the surface
self-diameter x 2

No cracks
found onthe surface

Heat deformation120℃ x 1 hr
Load: 2.45 N for insulation thickness lessthan 0.76 mm
3.92 N for insulation thickness notless than 0.76 mm

28%

5%

Flame resistance

VW-1

PassedPassedExternal damage test conditions: r=0.125 mm,
load=800 g x 10 times
Photo 1

Characteristics of EcoacePlus Series.

Item

Material
property

Wire ends of EcoacePlus.

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New Chemical Cross-Linked Halogen-Free Insulated Wire “EcoacePlus Series”

4.

CONCLUSIONS

We have recently developed a new cross-linking technology, and have added to our product lineup EcoacePlus
Series of significantly improved resistance against external damages. Through unification of substitution products
for general heat-resistant PVC electric wires with a rated
temperature of 105 ℃� into EcoacePlus Series, we intend
to expand the employment of halogen-free electric wires,in conjunction with EcoBeamex Series for high-rated temperatures of 125 ℃� and 150 ℃�, in the marketplace ofelectric wires for electric equipment.
For more information, please contact:
Electronic Wire and Cable Group, Telecommunications
and Network Systems Sales Department,
Telecommunications Company.
TEL: +81-3-3186-3189
FAX: +81-3-3186-3900

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200627