ELECTRICAL WIRE AND CABLE

Abstract: An electrical wire or cable has electrical insulation or a jacket which comprises a cross-linked blend of: (a) an aromatic polymer that has a char residue of at least 25 % at 850 DEG C and contains one or more aliphatic moieties; and (b) a polymer having a char residue of not more than 15 % at 850 DEG C; the blend containing at least 20 % by weight of the aromatic polymer based on the total weight of the polymer but having an overall molar carbon to hydrogen ratio of not more than 1.15. The wire insulation exhibits reduced erosion compared with the uncross-linked insulation when subjected to a tracking test, and exhibits a disproportionately reduced char residue, compared with the char residue of the components, which leads to a high degree of electrical tracking resistance.

Description: Electrical Wire and Cable This invention relates to electrical wire and cable, and especially to wire and cable that employ electrical insulation based on aromatic polymers. Electrical wire and cable that use aromatic polymer insulation have been used for many years in numerous applications. For example wires that employ polyimide wraps or tapes usually bonded with fluoro- polymer adhesive layers have been used extensively as aircraft wire, for both civil and military applica¬ tions. Other examples of aromatic insulation that have been used for equipment wire or "hook-up" wire, air frame wire and . in wire harnesses include aromatic polyether ketones, polyether ether ketones, modified polyphenylene oxide, and polyimide amides. Highly aro¬ matic polymers have been used successfully in many applications because they have a range of desirable properties especially high strength and toughness, abrasion resistance, temperature resistance, dielectric strength and are often inherently highly flame- retarded. The combination of these properties has enabled wire and cable fabricated from these polymers to be used in small lightweight constructions . Such constructions have been used increasingly in both mili- tary and civil applications due to the high density and complexity of modern electrical systems. However, these highly aromatic polymers suffer from a major problem: they are particularly suscep¬ tible to tracking. Tracking is a phenomenon associated with the formation of permanent and progressive con¬ ducting paths on the surface of the material by the combined effects of an electrical field and external surface pollution. Once commenced, the carbonaceous conducting deposits often extend quickly in dendritic fashion to give a characteristic "tree" pattern until failure occurs across the surface. Electrical tracking can occur when a damaged energised bundle of wires become wet e.g. from electrolytes or condensation. This tracking may lead to flashover and arcing that causes additional wires in the bundle to become damaged. A catastrophic cascade failure can result from a fault to a single wire if adjacent wires that are at a different electrical potential are also susceptible to tracking or if the bundle is in contact with a grounded structure. Tracking can occur at low voltages e.g. 100V a.c. or less but becomes less likely as the voltage is reduced. A related phenomenon, to which these polymers are also highly susceptible, is that of breakdown due to arcing. In this case a potential difference between two conductors, or between a conductor in which the insulation has been mechanically damaged, and ground, can result in the formation of an arc between the con¬ ductors or between the conductor and ground. The high temperature of the arc causes the polymer to degrade extremely rapidly and form an electrically conductive carbonaceous deposit which can extend rapidly, as with wet tracking, and lead to catastrophic failure in which many or all of the wires in a bundle are destroyed. Arcing can occur at very low voltages, for example 24V d.c. or lower, and since, unlike tracking, no electro¬ lyte or moisture is involved, it is a particularly hazardous phenomenon. Arcs may also be struck by drawing apart two conductors between which a current is passing as described for example by J.M. Somerville "The Electric Arc", Methuen 1959. Another phenomenon that can be associated with tracking and arcing is erosion. In this case insu¬ lating material is removed by a vaporization process originated by an electrical discharge without the for¬ mation of electrically conductive deposits so that failure of the insulation will not occur until complete puncture of the insulation occurs. According to the present invention, there is pro¬ vided an electrical wire having electrical insulation or a cable having a jacket which comprises a crosslinked blend of: (a) an aromatic polymer that has a carbonaceous char residue of at least 25% and contains one or more aliphatic moieties; and (b) a polymer having a carbonaceous char residue of not more than 15%; the blend containing at least 20% by weight of the aro¬ matic polymer based on the total weight of the polymer but having an overall molar carbon to hydrogen ratio (C/HΪ of not more than 1.15. The char residue of the polymer components in the alectricai wire according to the invention can be measured by the method known as thermogravimetric ana¬ lysis, or TGA, in which a sample of the polymer is heated in nitrogen or other inert atmosphere at a defined rate to a defined temperature and the residual weight, which is composed of char, is recorded. The char residue is simply the quantity of this residual char expressed as a percentage of the initial polymer after having taken into account any non polymeric vola¬ tile or non-volatile components. The char residue values quoted herein are defined as having been measured at 850°C and with a heating rate of 10°C per minute. Many aromatic polymers will have a char resi¬ due of at least 30%, some polymers having a char resi¬ due of at least 40% and even at least 50%. This does not mean to say that a high char value is desired for its own sake, but simply that good mechanical and phy¬ sical properties of these aromatic polymers including temperature stability and fire retardancy, are usually associated with high char residues. The preferred aromatic polymers which are used in this invention are well known to those skilled in the art, and reference may be made for example to U.S. Patents Nos. 3,025,605, 3,306,874, 3,257,357, 3,354,129, 3,441,538, 3,442,538, 3,446,654, 3,658,9.38, 3,677,921, 3,838,097, 3,847,867, 3,953,400, 3,956,240, 4,107,147, 4,108,837, 4,111,908, 4,175,175, 4,293,670, 4,320,224, 4,433,088 and 3,446,654, British Patents Nos. 971,227, 1,369,210, 1,599,106 and 2,163,759A and European Patent Applications Nos. 170,065, 124,276 and 178,185. The disclosures of these specifications are incorporated herein by reference. The most preferred polymers are polyether imides and polyphenylene oxides although polymers such as polyketones , polyether keto¬ nes, polyether et.ier ketones, polyether sulphones and polyether ketone/sulphone copolymers may be used pro¬ vided they include aliphatic moieties. Blends of dif¬ ferent polymers can be used. The aliphatic moieties of the aromatic polymer may comprise pendant alkyl groups or may comprise alkylene groups in the polymer back¬ bone. Preferably the or each aliphatic moiety has not more than 4, and more preferably not more than 3 carbon atoms . In the case of pendant alkyl groups, each group is most preferably a methyl group, while in the case of alkylene groups each group preferably has not more than 3 carbon atoms, and especially only one carbon atom, in the chain backbone, for example a methylene or isopro- pylidine group. Preferred aromatic polymers are polymers with a melting or softening point of at least 250°C, par¬ ticularly at least 300°C and which may be crystalline or amorphous. Softening points of amorphous polymers may conveniently be measured by thermomechanical analy¬ sis (TMA), in which case the softening point refers to the temperature at which the probe has reached 60% penetration. In one class of such polymers the polymer comprises units of the formula -Ar-Q- the units being the same or different, wherein Ar represents a divalent aromatic radical that is substituted with one or more aliphatic groups, and Q represents -0-, -S-, -SO2-, -CO-, -NH-CO- or -C00-, or Ar represents a tri-valent radical and Q represents C0- -N CO- each bond of the Q radical preferably being bonded directly to an aromatic carbon atom. One preferred class of polymer comprises the polyphenylene oxides of the repeating unit in which the groups R]_, which may be the same or dif¬ ferent, each represents an aliphatic group having no tertiary alpha carbon atom, and preferably a methyl group. In another class of aromatic polymers the aromatic polymer is a crystalline polyarylene ether comprising recurring units of the formula -O-E-O-E'- where E is the residue of a dihydric phenol and E' is the residue of an aromatic compound having an electron withdrawing group in at least one of the positions ortho and para to the valence bonds, the E and E 1 radi¬ cals being linked to the -0- radicals through aromatic carbon atoms. In one preferred sub-class, E may be a radical of the formula wherein R 2 is a divalent radical; x is 0 or 1; Y and Y' which may be the same or different each represents a halogen atom, alkyl radical containing 1 to 4 carbon atoms or alkoxy radical containing 1 to 4 carbon atoms; y and z independently of one another are 0 or an integer of up to 4 and E' is a radical of the formula wherein R3 is a sulphone, carbonyl, vinyl, sulphoxide, azo, saturated fluorocarbon, organic phosphine oxide or ethylidene radical at least one of the radicals R 2 , R3, Y or Y 1 being aliphatic. In this class preferred poly- sulphones are those in which y and z are 0, x is 1, R3 is a sulphone radical and R 2 is a radical of the for¬ mula *4 -C- 1 R 4 wherein each of R4 is independently selected from hydrogen atoms; alkyl radicals containing 1 to 4 carbon atoms which may be unsubstituted or substituted by one or more halogen atoms; aryl, alkaryl and aralkyl radi¬ cals containing 6 to 10 carbon atoms which may be unsubstituted or substituted by one or more halogen atoms . In another class of aromatic poiymers , the polymer is a polyether imide or polysulphone imide which comprises recurring units of the formula where Q is -0- or -S0 2 -, Z is a trivalent aromatic radical, R5 is a divalent aromatic radical that inclu¬ des an alkylene moiety and Rg is a divalent organic radical, the polymer preferably having the formula: in which D represents a group of the formula: R' represents an aryl.ene group. Another class of polymers is the polyetherketones that* have repeating groups comprising aromatic ether and aromatic ketone groups together with an imide, amide, ester, benzoxazols or benzothiazoie group pro¬ vided, as stated above, the polymer contains an alipha¬ tic group. Yet another class of aromatic polymer is the polyarylates. Polyarylates that may be used include those that are derived from dihydric phenols and at least one aromatic dicarboxylic acid. Examples of such polymers include those derived from a dihydric phenol of the general formula in which the groups Y, which may be the same or dif¬ ferent, each represent a hydrogen atom, a C]_ to C4 alkyl group, or.a chlorine or bromine atom; b is 0 or an integer from 1 to 4; Re represents a divalent saturated or unsaturated hydrocarbon group, e.g. an alkylene, alkylidine, cycloalkylene or cycloalkylidine group, an oxygen or sulphur atom or a carbonyl or sulphonyl group; and c is 0 or 1. Preferred aromatic polymers consist essentially of repeating units having one of the following formulae (3) or in which units derived wholly from isophthalic acid or terephthalic acid or a mixture of both are present. Blends of any two or more of the above polymers may be employed as may copolymers based on any two or more of these polymers. In addition, blends of any of the above polymers with other wholly aromatic polymers (i.e. having no aliphatic moieties) may be employed. The preferred aromatic polymers will usually have a molar C:H ratio of at least 1.0, preferably at least 1.2, more preferably at least 1.3 and especially at least 1.4. The toughest polymers such as the polyetherimides, which are associated with high char residues, will have C:H ratios greater than 1.5. The polymer blends used to form the insulation preferably contain at least 30% by weight aromatic polymer, more preferably at least 50% and especially at least 60% by weight aromatic polymer based on the total polymeric component, the term aromatic polymer as used herein meaning polymers having a sufficiently high pro¬ portion of aromatic rings that the polymer has a char residue of at least 25%. More than one such polymer may be used. Polymer (b) may, at least in the broadest aspect, be any organic polymer, including copolymers and blends of polymers, having a char residue of not more than 15%, preferably not more than 10%, more preferably not more than 5% and most especially not more than 2%, the most preferred polymers often having char residues of 0%. It is possible for the polymer to include one or more aromatic moieties in addition to its aliphatic moieties, and indeed a number of preferred polymers do so. However the polymer should have sufficient alipha¬ tic .nature that the C:H ratio is not more than 1. Examples of aliphatic polymers and polymers containing aliphatic moieties (which will be referred to herein simply as aliphatic polymers for the sake of brevity) include olefin homopolymers and copolymers of olefins with other olefins and with other monomers e.g. vinyl esters, alkyl acrylates and alkyl alkacrylates, e.g. low, medium and high density polyethylene, linear low density polyethylene and ethylene alpha-olefin copoly¬ mers, ethylene/propylene rubber, butyl rubber, ethylene vinyl acetate, ethylene ethyl acrylate and ethylene acrylic acid copolymers, and linear or radial styrene diene di- or tri-block copolymers e.g. styrene/buta- diene, styrene/isoprene copolymers, styrene/butadiene/- styrene and styrene/isoprene/styrene, and hydrogenated versions of these block copolymers especially styrene ethylene/butylene/styrene block copolymers. A par¬ ticularly preferred class of low charring polymers is the polyamides . Preferred polyamides include the nylons e.g. nylon 46, nylon 6, nylon 7, nylon 66, nylon 610, nylon 611, nylon 612, nylon 11 and nylon 12, nylon 1212 and aliphatic/aromatic polyamides, polyamides based on the condensation of terephthalic acid with trimethylhexamethylene diamine (preferably containing a mixture of 2,2,4- and 2,4,4-trimethylhexamethylene diamine isomers) , polyamides formed from the conden¬ sation of one or more bisaminomethylnorbornane isomers with one or more aliphatic, cycloaliphatic or aromatic dicarboxylic acids e.g. terephthalic acid and optionally including one or more amino acid or lactam e.g. £-caprolactam comonomers, polyamides based on units derived from laurinlactam, isophthalic acid and bis-(4-amino-3-methylcyclohexyl) methane, polyamides based on the condensation of 2,2-bis-(p-aminocyclo- hexyl) propane with adipic and azeleic acids, and polyamides based, on the condensation of trans cycio- hexane-l,4-dicarboxylic acid with the trimethyihexa- methylene diamine isomers mentioned above. Other aliphatic polymers that may be used include polyesters e.g. polyalkylene terephthalate and especially poly- tetramethylene terephthalate, and cycloaliphatic diol/terephthalic acid copolymers e.g. copolymers of terephthalate and isophthalate units with 1,4-cyclo- hexanedimethyloxy units, polysulphides, polyethers e.g. polybutylene ether copolymers, and especially polyether esters such as those having polytetramethylene ether and polytetramethylene terephthalate blocks; aliphatic ionomers e.g. those based on metal salts of ethylene (meth)acrylic acid copolymers or sulphonated olefins such as sulphonated EPDM, and the like. Preferred aliphatic polymers include the polyamides mentioned above, polyethylene, polybutylene terephthalate, iono¬ mers based on metal salts of methacrylated polyethy¬ lene, acrylic elastomers e.g. those based on methyl, ethyl or n-butyl acrylate or alkoxy-substituted ethyl or n-butyl acrylate polymers containing a cure site monomer and optionally ethylene comonomer, and block copolymers having long chain ester units of the general formula: 0 0 • II II -OGO-C-R-C- and short-chain ester units of the formula 0 0 -ODO-C-R-C- in which G is a divalent radical remaining after the removal of terminal hydroxy1 groups from a polyalkylene oxide) glycol, preferably a poly (C to C4 alkylene oxide) having a molecular weight of about 600 to 6000; R is a divalent radical remaining after removal of carboxyl groups from at least one dicarboxylic acid having a molecular weight of less than about 300; and D is a divalent radical remaining after removal of hydroxyl groups from at least one diol having a molecular weight less than 250. Preferred copolyesters are the polyether ester polymers derived from terephthalic acid, polytetramethylene ether glycol and 1,4-butane diol. These are random block copolymers having crystalline hard blocks with the repeating unit: - ( CH 2 ) and amorphous, elastomeric polytetramethylene ether terephthalate soft blocks of repeating unit having a molecular weight of about 600 to 3000, i.e. n = 6 to 40. Other preferred aliphatic polymers include those based on polyether and polyamide blocks, especially the so called a "polyether-ester amide block copolymers" of repeating unit: -C-A-C-O-B-O- II II 0 0 wherein A represents a polyamide sequence of average molecular weight in the range of from 300 to 15,000, preferably from 800 to 5000; and B represents a linear or branched polyoxyalkylene sequence of average molecu¬ lar weight in the range of from 200 to 6000, preferably from 400 to 3000. Preferably the polyamide sequence is formed from alpha,omega-aminocarboxylic acids, lactams or diamine/- dicarboxylic acid combinations that include C4 to C14 alkylene carbon chains, and the polyoxyalkylene sequence is based on ethylene glycol, propylene glycol and/or tetramethylene glycol, and the polyoxyalkylene sequence constitutes from 5 to 85%, especially from 10 to 50% of the total block copolymer by weight. These polymers and their preparation are described in UK Patent Specifications Nos. 1,473,972, 1,532,930, 1,555,644, 2,005,283A and 2,011,450A. Other aliphatic polymers e.g. poly 1,12-dodeca- methylene pyromellitimide or 1,13-tridecamethylene pyromellitimide, as described in U.S. patent No. 3,551,200, may be used. The aliphatic polymer preferably has a C:H ratio of not more than 0.9, more preferably not more than 0.75, most preferably not more than 0.65 and especially not more than 0.55. The polymer blends that are used in the wire and cable according to the invention have the advantage that they generally exhibit significantly reduced susceptibility to tracking and to arcing. In par¬ ticular, we have found that the propensity of the polymer blend to char when subjected to elevated tem¬ peratures, and accordingly the degree of tracking and arcing of the blend, is often reduced dispropor¬ tionately to the quantity of aliphatic polymer in the blend. Thus it is possible to form blends of polymers with desirable physical and mechanical properties but without the tendency of the polymer to track and arc. For example the polymeric material (including any fillers) will preferably have an elongation to break of at least 50% and especially at least 100% and a cut through value at 150°C of at least 15, preferably at least 20 N. Thus, according to another aspect, the invention provides an electrical wire or cable having electrical insulation or a jacket which comprises a crosslinked blend of: (a) an aromatic polymer that has a char residue of at least 25% at 850°C and contains one or more aliphatic moieties; and (b) a polymer having a char residue of not more than 15% at 850°C; the blend containing at least 20% by weight of the aro¬ matic polymer based on the total weight of the polymer but having sufficient polymer (b) to reduce the cnar residue of the blend to not more than 20%. In addition to the reduction in the tracking and arcing of the polymer blends, we have observed that at least some of the polymeric blends used in the present invention exhibit significantly a reduced tendency to erode than the same or similar polymer systems that are not cross-linked. Erosion is a phenomenon in which insulating material is removed by a vaporization pro¬ cess originated by an electrical discharge without the formation of electrically conductive deposits, so that failure of the insulation will not occur until complete puncture of the insulation occurs. The idealised con¬ cept does not always occur in practice, and many materials may exhibit both tracking and erosion. The two phenomena are distinguished from each other in that tracking (and arcing) are phenomena which produce a conducting char, often with little volume change in the insulation, whereas pure erosion can generate signifi¬ cant volume changes in the insulation with no con¬ ducting char, and may be tested for by determining the change in weight of the insulation or rate at which material is lost during this process (erosion rate) . Although the polymeric blend is described as being crosslinked, this does not mean that both or all com¬ ponents of the blend are crosslinked or crosslinked to the same extent. In general the aromatic polymer will exhibit a lower degree of crosslinking than the alipha¬ tic polymer, and in many cases the aliphatic polymer may be highly crosslinked while the aromatic polymer remains substantially uncrosslinked. The polymeric composition may be cross-linked, for example, by exposure to high energy radiation. Radiation cross-linking may be effected by expos¬ ure to high energy irradiation such as an electron beam or gamma-rays. Radiation dosages in the range 20 to 800 kGy, preferably 20 to 500 kGy, e.g. 20 to 200 kGy and particularly 40 to 120 kGy are in general appropriate depending on the characteristics of the polymer in question. For the purposes of promoting cross-linking during irradiation, preferably from 0.2 to 15 weight per cent of a prorad such as a poly- functional vinyl or allyl compound, for example, triallyl cyanurate, triallyl isocyanurate (TAIC), methylene bis acrylamide, metaphenylene diamine bis maleimide or other crosslinking agents, for example as described in U.S. patents Nos. 4,121,001 and 4,176,027, are incorporated into the composition prior to irra¬ diation. The polymeric composition may include additional additives, for example reinforcing or non-reinforcing fillers, stabilisers such as ultra-violet stabilisers, antioxidants, acid acceptors and anti-hydrolysis stabi¬ lisers, pigments, processing aids such as plasticizers, halogenated or non-halogenated flame retardants, fungi¬ cides and the like. In many instances the wire may have only a single insulating layer. However it is possible, and often desirable for it to include one or more additional layers that are provided for other reasons. Thus, for example, the aromatic blend described herein may be employed in a dual-wall construction as a primary jacket on top of a primary insulation that comprises an aliphatic polymer having a high comparative tracking index (C.T.I.) (e.g. above 300) or a different aromatic/aliphatic blend, e.g. one having a higher C.T.I. The polymer blend may be emoloyed on top of an inorganic arc control layer for example formed by a vacuum deposition process, or a wet-tracking control layer formed for example by another aliphatic polymer having a high C.T.I, (e.g. above 300) may be provided on top of the polymer blend. Alternatively the layer may be used as a primary insulation with an aromatic or non-aromatic primary jacket on top of the layer. Two or more of these additional layers may be provided in constructions having three or more layers. The aliphatic polymer may be one ' of those polymers mentioned above for use in the blend with the aromatic polymer. However, one class of aliphatic polymer that is particularly useful is the fluorinated polymers, preferably those containing at least 10%, more pre¬ ferably at least 25% fluorine by weight. The fluorin¬ ated polymer may be a single fluorine containing polymer or a mixture of polymers one or more of which contains fluorine. The fluorinated polymers are usually homo- or copolymers of one or more fluorinated, often perfluorinated, olefinically unsaturated monomers or copolymers of such a comonomer with a non- fluorinated olefin. The fluorinated polymer preferably has a melting point of at least 150°C, often at least 250°C and often up to 350°C, and a viscosity (before any crosslinking) of less than 10 4 Pa.s at a tem¬ perature of not more than 60°C above its melting point. Preferred fluorinated polymers are homo- or copolymers of tetrafluoroethylene, vinylidine fluoride or hexa- fluoropropylene, and especially etnyiene/tetrafluoro- ethylene copolymers e.g. containing 35 to 60% ethylene, 35 to 60% tetrafluoroethylene by mole and up to 10% by mole of other comonomers, polyvinylidine fluoride, copolymers of vinylidine fluoride with hexafluoro- propylene, tetrafluoroethylene and/or hexafluoroiso- butylene, polyhexafluoropropylene, and copolymers of hexafluoropropylene and tetrafluoroethylene. Alter¬ natively C -Cs perfluoroalkoxy substituted perfluoro- ethylene homopolymers and copolymers with the above fluorinated polymers may be used. The wires and cables according to the invention may be formed by conventional techniques . For example the polymers may be blended together in a mixer, together with any additional components, pelletised, and then extruded onto a wire conductor and for this reason it is preferred for the polymers used in the invention to be melt-shapable so that the wire insula¬ tion can be formed by extrusion. The wires may be used individually as equipment or "hook-up" wires, or airframe wires, or in bundles and harnesses, both jacketted and unjacketted, and may be used in multiconductor cables. The wires, harnesses or cables may be unscreened or they may be provided with a screen to protect them from electromagnetic inter¬ ference, as well known in the art. In addition flat cables may be formed using the insulation materials according to the invention, either employing flat con¬ ductors or round conductors . The invention will be described by way of example with. reference to the accompanying drawings in which: Figure 1 is an isometric view of part of an electrical wire according to the invention; Figure 2 is a schematic view of the test arrange¬ ment for wet tracking; and Figure 3 is a schematic view of the test arrange¬ ment for dry arcing. Referring initially to figure 1 of the accompany¬ ing drawings an electrical wire comprises a conductor 11 which may be solid or stranded as shown and is optionally tinned. On the conductor an inner insu¬ lating layer 12 or primary insulation has been extruded. The insulation is formed from nylon 12 or a blend of nylon 12 with a polyaryl ether imide which contains about 5% by weight triallyl isocyanurate crosslinking promotor. After the inner layer 12 has been formed an outer layer 13 or primary jacket formed from an ethylene-tetrafluoroethylene copolymer, con¬ taining about 7% by weight triallyl isocyanurate cross¬ linking promotor, is extruded on the inner layer 12. Each layer has a wall thickness of about 100 urn. After both layers have been extruded the insulation is irra¬ diated by high energy electrons to a dose of about 120 kGy. The following Examples illustrate the invention: WET ' TRACKING TEST This test is designed to simulate the condition occuring when a damaged wire bundle comes into contact with an electrolyte. Under actual conditions, the electrolyte may be moisture containing dust particles or other ionic contaminant. Damage to the bundle may occur through a number of reasons e.g. abrasion, hydro¬ lysis of the insulation, ageing, etc. Current flow through the electrolyte results in heating and evapora¬ tion of the solution. This causes one or more dry bands to appear across which the test voltage is dropped, resulting in small, often intense, scin¬ tillations which damage the insulation. Figure 2 shows the sample set-up. A wire bundle 1 is prepared from seven 18cm lengths 2 of 20AWG tinned- copper conductor coated with a layer of the material under test. The bundle 1 is arranged with six wires around one central wire and is held together using tie wraps 3 so that the wires are not twisted. Two adja¬ cent wires are notched circumferentially to expose 0.5mm bare conductor on each wire. The notches 4 are arranged such that they are 5mm apart with the tie wraps 5mm either side of them. One end of each wire is stripped to enable connections to be made to the power supply via insulated crocodile clips The sample is held at an angle of 30 degrees to the horizontal using a simple clamp made of an electrically insulating resin so that the damaged wires are uppermost and the stripped ends are at the upper end of the bundle. A piece of filter paper 5 20 x 10mm wide is wrapped around the bundle approximately 2mm above the upper notch; this is best held in place with the upper tie wrap. A peristaltic pump conveys the electrolyte from the reservoir to the sample via a dropping pipette 5, and a power supply is provided to energise the bundle. The electrolyte used is 2% sodium chloride and option¬ ally 0.02% of an ammonium perfluoroalkyl carboxylate surfactant in distilled or deionised water. The pump is set to deliver this solution at a rate of approxima¬ tely lOOmg per minute through the pipette 6 which is positioned lOmm vertically above the filter paper 5. The power is supplied by a 3-phase 400Hz 115/200V generator of at least 5kVA capacity or a single phase 50Hz 115V transformer of at least 3kVA capacity. A device for recording time to failure is provided which records the time when either a wire goes open circuit, or when a circuit breaker comes out. Leakage currents can be followed with the use of current clamps surrounding the wires and connected to a suitable oscilloscope. In the case of the three phase supply, adjacent wires of the bundle are connected to alternate phases of the power supply via 7.5A aircraft-type circuit breakers e.g. Klixon with the central wire connected directly to neutral. In the case of the single phase supply, alternate wires are connected to neutral with the remaining wires including the central conductor to live. A few drops of electrolyte are allowed to fall onto the filter paper to ensure saturation prior to starting the test. The power is switched on and the timer started. The test is allowed to continue until: a) one or more circuit breakers come out; b) a wire becomes open circuit; or c) 8 hours have elapsed. The condition of nhe final bundle and the cime to failure is noted in all cases. Where failure has occurred due to breakers coming out, the power is then reapplied and each breaker is reclosed in turn until there is no further activity. The condition of the bundle is again noted. Failure due to the wire becoming open circuit (result (b)) is indicative of erosion. If failure occurs due to one or more circuit breakers coming out (result (a)) then the absence of further crepitation on resetting of the circuit breakers indicates failure due to erosion, while further crepitation indicates tracking failure. Dry Arc Test This test is designed to simulate what happens when a fault in a wire bundle causes arcing under dry conditions. A graphite rod is used to initiate the arc which causes thermal degradation of the insulation. Continuation of the fault current can only occur through the wire bundle under test due to shorting across adjacent phases through a conductive char, or direct conductor-conductor contact such as might occur if the insulation is totally removed by the duration of the arc. Figure 3 shows the sample set-up. A wire bundle 21 is prepared from seven 10cm lengths 22 of 20AWG tinned-copper conductor coated with a layer of the material under test. The bundle 22 is arranged with six wires around one central wire and held together with tie wraps spaced about 5cm apart. One of the outer wires is notched circumferentially between che tie wraps to expose 0.5mm bare conductor and one end of each wire is stripped to enable connections to be made via insulating crocodile clips. A rod 23 is provided which is made of a spectrographically pure graphite, diameter 4.6mm, with an impurity level not more than 20ppm. It is prepared before each test by sharpening one end using a conven¬ tional pencil sharpener of European design to give an angle of 10 degrees off vertical with a tip diameter of 0.4±0.1mm. A lOOg weight 24 is clamped onto the top of the rod 23 to maintain contact during the arc ini¬ tiation and also acts as a device to limit the depth of penetration of the rod by restricting its downward tra¬ vel. The rod passes through a PTFE bush which allows it to slide freely up and down. The arrangement of levers enables precise posi¬ tioning of the rod 23 on the wire bundle 21 which is held securely in place by means of a simple clamp 25 made of an electrically insulating resin and mounted on a block 26 made of the same material. The power source can be either: a) a 3-phase 400Hz 115/200V generator of at least 5kVA capacity b) a single phase 50Hz 115V transformer, at least 3kVA capacity c) 24V d.c. supplied by two 12V accumulators. The fault current is detected by means of current clamps surrounding the connecting leads and the voltage at failure is measured using a 10:1 voltage probe. The transducer signals are fed into a multi-channel digital storage oscilloscope where they can be displayed and manipulated to obtain power curves (voltage x current) and energy (integration of power curve). The wire bundle 21 is positioned in the clamp 25 so that the notched wire is uppermost. Adjacent wires of the bundle are connected to different phases of the supply through 7.5A aircraft type circuit breakers, and the central wire is connected directly to neutral. In the case of single phase or d.c. supplies, alternate wires are connected to neutral or the negative ter¬ minal, with the remaining wires, including the central wire, connected through circuit breakers to live or the postive terminal. The carbon rod is also connected to neutral or the negative terminal and positioned so that the point is in contact with ' the exposed conductor. The gap between the lOOg weight and the PTFE bush is adjusted to 0.4 mm using a suitable spacer to limit the penetration of the rod into the sample. A voltage probe is connected across the damaged wire and the rod, and current clamps positioned on each of the three pha¬ ses, or on the wires connected to the live side of the supply. A protective screen is placed in front of the test set-up and the power switched on. A material is deemed to pass this test if: a) no circuit breakers come out and the activity is relatively non-eventful, or b) there is no further activity on resetting the breakers after a non-eventful test. .In addition, non-tracking materials will have relatively few spikes in the current trace with a correspondingly low total energy consumed. Tracking materials, on the other hand, show many spikes usually on all three phases, which are accompanied by violent crepitation and large energy consumption. CTI Test This method is a modification of IEC 112 which measures the low voltage track resistance (up to 600V) as Comparative Tracking Index (CTI) of materials in the presence of an aqueous contaminant. The samples are prepared by extruding tapes of the required composition approximately 0.5 mm thick and of sufficient width to ensure that during the test no liquid flows over the edge of the sample. Before testing, the surface of the sample is cleaned with methanol to remove any surface contamination. The test apparatus is as described in IEC 112. It consists of two platinum electrodes, each with one end chisel-shaped to an angle of 30 degrees. The electro¬ des are symmetrically arranged such that the opposing chisel faces are vertical and 4.0±0.1mm apart when placed on the surface of the specimen. The power supply consists of a 0.5kVA transformer capable of supplying an a.c. voltage in the range 100-600V at 50Hz. A rheostat is incorporated into the circuit so that the short circuit current may be adjusted to give l.O±O.l amp. An over-current relay is provided which shuts off the HV supply when a current of at least 0.5 amps flows for 2 seconds, the criteria for failure. A device for dropping electrolyte solution between the electrodes is provided. This consists of a peristaltic pump which draws liquid from a reservoir and pumps it out of a needle situated at height of 30-40mm above and between the electrodes. The dropping rate is set to 1 drop every 30=5 seconds with a drop volume of 20=3 xaax ' . Before the test, the needle is cleaned and purged with several drops of electrolyte to ensure the correct concentration of reagent is used. The electrolyte solution used in these tests is 0.1=0.002% ammonium chloride and 0.01% sodium dodecyl sulphate surfactant in deionised water and has a resistivity of 405=5 ohm.cm at 23°C. By using a surfactant, reproducible results have been obtained on homogeneous samples . However, the type of surfactant used can greatly affect the CTI values obtained. Sodium dodecyl sulphate was chosen as this gave a working range of below 150V (for known badly tracking materials ) to above 600V for non- tracking materials. Test Procedure The specimen is put into position and the electro¬ des lowered on to the surface. A suitable voltage is chosen and the short circuit current adjusted accor¬ dingly. The electrolyte is then allowed to drop bet¬ ween the electrodes until either a) tracxmg occurs b) at 600V, the sample withstands 50 drops. For those materials which track, the test is then repeated at at least three other voltages such that two voltages give results above 50 drops, and two give results below 50 drops. A curve of drops to failure versus applied voltage is plotted from which is read the voltage at which 50 drops would cause failure. This voltage is the comparative tracking index (CTI). For those materials which withstand 50 drops at 600V, CTI is then quoted as >600 and the erosion rate of the sample is determined by measuring the thickness of the material and the time taken for the electrodes to penetrate through to the base at 400V. Erosion rate is then quoted as mm minute * "^. In the Examples the following polymers are used: Polyarylate: A polymer having a repeat unit of for¬ mula. Polyaryletherketone: A polymer having a repeat unit of formula: Polycarbonate: A polymer having a repeat unit of the formula: Polyetherimide: A polymer having a repeat unit of for¬ mula: Polyethersulphone: A polymer having a repeat unit of formula: Polyetherblock amide: A polymer having a repeat unit of the formula: 0 0 il 11 -C-PA-C-0-PE-0- where PA represents the polyamide segment and PE repre¬ sents the polyether segment. Polyamide I: A polymer formed from a mixture of 2,2,4-, and 2,4,4-trimethyhexamethylene diamine and terephtha¬ lic acid (ex Dynamit Novel). Polyamide II: A polymer formed from a mixture of laurinlactam, bis-(4-amino-3-methylcyclohexyl) methane and isophthalic acid (ex EMS Chemie). Ionomer Resin: Surlyn 9090 from DuPont Amide Resin: Selar PA obtained from DuPont Poly(ether-ester) block copolymer: A block copolymer comprising approximately 57% by weight polybutylene terephthalate hard blocks and approximately 43% by weight poly(butylene glycol polyether terephthalate) soft blocks. Polyester Amide: An elastomer having polyester blocks formed from nonane dioic acid/1,4-butanediol reacted with 1,1'-methylene bis (isocyanatobenzene) . Polyphenylene Oxide: A polymer having the repeat unit: Polyethersulphone II: A polymer having the repeat unit: EXAMPLES Various blends of aromatic polymers with aliphatic polymers and cross-linking agents were produced using a Baker Perkins twin-screw extruder. The mixing con¬ ditions were varied according to the melting charac¬ teristics of the polymeric constituents. Plaques, 3mm thick, were prepared from the blend using a hot compression moulding press. In other Examples the polymers were dry blended and extruded directly as a tape ( 0.5 mm thick and 15 mm wide) instead of being formed as plaques. The blends were extruded onto 22 AWG tin-plated copper wire unless otherwise stated using a 20mm Baughan extruder. The plaques and wire samples were cross-linked, unless otherwise indicated, by exposure to an electron beam for a dosage of 100-200 kGy. The wires and plaques were subjected to che com¬ parative tracking index and dry tracking test and in some cases the wet tracking test, and the char values of the blends were measured. The molar C:H ratios and char residue values for the aliphatic polymers are given in Table I, and the test results are given in Table II. The actual and predicted char residue values for Examples 1 to 5 and Control A are shown graphically in Figure 4. TΆBL_Ξ I Note (i) Molar C/H ratio calculated from the structure of the repeat unit of polymers except where marked * in which case it was obtained from carbon/hydrogen/nitrogen analysis of the polymers . - 34 - Samples of blends of a polyarylate with a range of aliphatic polymers to varying loadings were formed and tested as described above. The samples had the following compositions: Parts by W≡i t • an__Le 10 11 12 13 14 15 C πtzdL A _olyaτy1 t * p 50 57.5 70 50 100 τv3Lαι 12 50 37.5 3) 40 20 D arad≥ resin 37.5 =£K_* ' 25 25 ' BI** 50 50 25 EA*** 40 8.3 CEE 8 5 5 5 Polyether ester block copolymer * * Polybutylene terephthalate *** Polyether block amide **** Triallyl isocyanurate The results arn shown in Table II. In addition the composition of Example 1 exhibited an erosion raζe of 0.018 mm minute-*-- as compared with a value of 0.061 mm minute"*'- for the equivalent un-crosslinked sample. IMEΠ (i) παlar C/H ratio oalαili-rt'flπl from srucute of repeat unit for pαlyπreis enεt vtøoe πβrted * in vhih case cttainad firm (ari_αvyrD^rviύtrogen analysis for pΛmers. siπple law o£ mixtures. Examples 16 to 28 Blends of a polyetherimide with a range of alipha¬ tic polymers were formed and tested as described above. The blends had the following compositions: Eδrts by weight EsatpLs 16 17 38 :19 20 21 22 23 24 25* 26 27 28* GtπrαL B &yeth_r 60 50 50 60 70 50 50 50 50 50 50 50 60 100 intife R±yarad≥ I 40 50 rylαi 12 50 40 30 pάlyetber 50 block amide R±yarrids π 50 icrarar resin 50 polyasta: 50 arrrid≥ EEBE 50 Wi\ 50 B±y-Φiteϋryl 50 επtSB EEHG 40 TAE 5 5 * Comparison The results are shown in Table III. (c) dαπpariscn repeat unit fi polyrers βfloept vtete πar __d * in vhich case obtained from Sxamples 29 to 34 Samples of blends of nylon 12 with a range of aro¬ matic polymers were formed and tested as described above. The samples had the following compositions. Parts by weight Example 29 30 31 32 33 34 Nylon 12 50 50 50 50 50 50 polycarbonate 50 ether-ketone 50 imide (comparison) Polyphenylene 50 oxide Polyaryl-ether 50 ketone (comparison) polyether sulphone 50 polysulphone 50 TAIC 5 5 5 5 5 5 The results are shown in Table IV together with the results for the following control runs: Control C Fluorinated ethylene/propylene bonded polyimide wrap Control D 80 parts by weight of polyethersulphone and 20 parts by weight of polyethylene terephthalate. Control E 80 parts by weight of polyethersulphone and 20 parts by weight of polybutylene terephthalate. Control F 80 parts by weight of polyethersulphone II and 20 parts by weight of polyethylene terephthalate. Control G 80 parts by weight of polyethersulphone II and 20 parts by weight of polybutylene terephthalate. TASGE ~ ~ 7 Prediction based on simple law of mixtures. In addition the composition of Example 29 exhi¬ bited an erosion rate of less than 0.005 mm minute"*'- as compared with an uncrosslinked value of 0.018 mm minute"^, and that of Example 34 exhibited a value of 0.027 mm minute"! as compared with a value of 0.052 mm minute"! for the uncrosslinked sample.

Claims: CLAIMS 1. An electrical wire or cable having electrical insulation or a jacket which comprises a crosslinked blend of: (a) an aromatic polymer that has a char residue of at least 25% at 850°C and contains one or more-aliphatic moieties; and (b) a polymer having a char residue of not more than 15% at 850°C; the blend containing at least 20% by weight of the aro¬ matic polymer based on the total weight of the polymer but having an overall molar carbon to hydrogen ratio of not more than 1.15. 2. A wire or cable as claimed in .claim 1, wherein the aromatic polymer has a char residue of at least 30% at 850 β C. 3. A wire or cable as claimed in claim 2, wherein the aromatic polymer has a char residue of at least 50% at 850°C. 4. A wire or cable as claimed in any one of claims 1 to 3, wherein the aromatic polymer has a molar carbon to hydrogen ratio of at least 1.0. 5. A wire or cable as claimed in claim 4, wherein the aromatic polymer has a molar carbon to hydrogen ratio of at least 1.3. ό . A wire or cable as claimed in any one of claims 1 to 5, wherein the aromatic polymer comprises a polyarylether, a polyarylate, a polyether imide or an aromatic polyester. 7. A wire or cable as claimed in claim 6, wherein the aromatic polymer comprises: i) units of the general formula: -Ar-Q- the units being the same or different, wherein Ar represents a divalent aromatic radical that is substituted with one or more aliphatic groups and Q represents -0-, -S-, -SO2-, -CO-, -NH-CO- or -COO-, or Ar represents a polyvalent radical and Q represents C0- -N [ \ CO- ii ) a crystalline polyarylene ether comprising recurring units of the formula: -O-E-O-E'- wherein E is radical of the formula: wherein R2 is a divalent radical; x is 0 or 1; Y and Y 1 which may be the same or different each represents a halogen atom, alkyl radical containing 1 to 4 carbon atoms or alkoxy radical containing 1 to 4 carbon atoms; y and z independently of one another are 0 or an integer of up to 4 and E' is a radical of the formula wherein R3 is a sulphone, carbonyl, vinyl, sulphoxide, azo, saturated fluorocarbon, organic phosphine oxide or ethylidene radical at least one of the radicals R2, R3, Y or Y 1 being aliphatic. iii) polyether imide or polysulphone imide which comprises recurring units of the formula where Q is -0- or -SO2, z is a trivalent aromatic radi¬ cal, R is a divalent aromatic radical that includes an alkylene moiety and R' is a divalent organic radical. 3. A wire or cable as claimed in claim 7, wherein the aromatic polymer has the general repeat unit: in which D represents a group of the formula: R" represents an arylene group. 9. A wire or cable as claimed in -claim 7, wherein the aromatic polymer comprises a polymer having a repeating unit of the formula: (1) ( 3 ) or in which the units may be derived wholly from terephthalic acid or isophthalic acid or both; 10. A wire or cable as claimed in any one of claims 1 to 9, wherein the polymer (b) has a char residue of not more than 10%. 11. A wire or cable as claimed in claim 10, wherein the polymer b has a char residue of not more than 5%. 12. A wire or cable as claimed in any one of claims 1 to 11, wherein the polymer (b) has a molar carbon to hydrogen ratio of not more than 0.75. 13. A wire or cable as claimed in claim 12, wherein the polymer (b) has a molar carbon to hydrogen ratio of not more than 0.65. 14. A wire or cable as claimed in any one of claims 1 to 13, wherein the polymer (b) comprises a polyole- fin, a copolymer of an olefin with an olefin, an alkyl acetate, an alkyl acrylate or a vinyl ester; a polyamide, a polyether, a polyester, an ionomer or an acrylic rubber. 15. A wire or cable as claimed in claim 14, wherein the polymer (b) comprises polyethylene, a crystalline polyamide, an amorphous aromatic/aliphatic polyamide, an ionomer based on a metal salt of methacrylated polyethylene, polybutylene terephthalate, a styrene/diene di- or tri-block copolymer or hydroge- nated version thereof or a block copolymer having long- chain ester units of the general formula: 0 0 H II -OGO-C-R-C- and short-chain ester units of the formula 0 O II II -ODO-C-R-C- in which G is a divalent radical remaining after the removal of terminal hydroxyl groups from a - 4 " poiyalkylene oxide) glycol, preferably a poly .C2 to C4 alkylene oxide) having a molecular weight of about 600 to 6000; R is a divalent radical remaining after removal of carboxyl groups from at least one dicarboxylic acid having a molecular weight of less than about 300; and D is a divalent radical remaining after removal of hydroxyl groups from at least one diol having a molecular weight less than 250. 16. A wire or cable as claimed in any one of claims 1 to 15, wherein the blend contains at least 50% by weight of the aromatic polymer, based on the total polymeric component. 17.. A wire or cable as claimed in claim 16, wherein the blend contains at least 60% by weight of the aroma¬ tic polymer based on the total polymeric component. 18. A wire or cable as claimed in any one of claims 1 to 17, wherein the blend has an overall molar carbon- to-hydrogen ratio of not more than 1.1. 19. A wire or cable as claimed in claim 18, wherein the blend has an overall molar carbon-to-hydrogen ratio of not more than 1.0. 20. A wire or cable as claimed in claim 19, wherein the blend has an overall molar carbon-to-hydrogen ratio of not more than 0.9. 21. A wire or cable as claimed in any one of claims 1 to 20, wherein the insulation or jacket has been formed by extrusion.

Inventors: DAY STEPHEN, PENNECK RICHARD JOHN, DAY, STEPHEN, PENNECK, RICHARD, JOHN
Applicants: RAYCHEM LTD, RAYCHEM LIMITED
Application year: 1988
Main classification: H01B3
IPC codes: C08L23, C08L53, C08L67, C08L69, C08L71, C08L79, C09D5, C09D167, C09D177, C09D179, H01B3