Poly insulation

As the demand for rubber increased so did the chemical industry s efforts to prepare a synthetic sub stitute One of the first elastomers (a synthetic poly mer that possesses elasticity) to find a commercial niche was neoprene discovered by chemists at Du Pont in 1931 Neoprene is produced by free radical polymerization of 2 chloro 1 3 butadiene and has the greatest variety of applications of any elastomer Some uses include electrical insulation conveyer belts hoses and weather balloons... 

Polyimide. Polyimide is a biaxiaHy oriented high performance film that is tough, flexible, and temperature- and combustion-resistant. Its room temperature properties compare to poly(ethylene terephthalate), but it retains these good characteristics at temperatures above 400°C. Its electrical resistance is good and it is dimensionally stable. The principal detriment is fairly high moisture absorbance. The main uses are for electrical insulation, particularly where high temperatures are prevalent or ionizing radiation is a problem. The films may be coated to reduce water absorption and enhance... 

Alumina trihydtate is also used as a secondary flame retardant and smoke suppressant for flexible poly(vinyl chloride) and polyolefin formulations in which antimony and a halogen ate used. The addition of minor amounts of either zinc borate or phosphoms results in the formation of glasses which insulate the unbumed polymer from the flame (21). 

The Fe, Co, and Ni deposits are extremely fine grained at high current density and pH. Electroless nickel, cobalt, and nickel—cobalt alloy plating from fluoroborate-containing baths yields a deposit of superior corrosion resistance, low stress, and excellent hardenabiUty (114). Lead is plated alone or ia combination with tin, iadium, and antimony (115). Sound iasulators are made as lead—plastic laminates by electrolyticaHy coating Pb from a fluoroborate bath to 0.5 mm on a copper-coated nylon or polypropylene film (116) (see Insulation, acoustic). Steel plates can be simultaneously electrocoated with lead and poly(tetrafluoroethylene) (117). Solder is plated ia solutioas containing Pb(Bp4)2 and Sn(Bp4)2 thus the lustrous solder-plated object is coated with a Pb—Sn alloy (118). 

CeUular polymers are also used for pipe and vessel insulation. Spray and pour-in-place techniques of appHcation are particularly suitable, and polyurethane and epoxy foams are widely used. Ease of appHcation, fire properties, and low thermal conductivity have been responsible for the acceptance of ceUular mbber and ceUular poly(vinyl chloride) as insulation for smaller pipes. 

Poly(phenylquinoxaline—arnide—imides) are thermally stable up to 430°C and are soluble in polar organic solvents (17). Transparent films of these materials exhibit electrical insulating properties. Quinoxaline—imide copolymer films prepared by polycondensation of 6,6 -meth5lene bis(2-methyl-3,l-benzoxazine-4-one) and 3,3, 4,4 -benzophenone tetracarboxyUc dianhydride and 4,4 -oxydianiline exhibit good chemical etching properties (18). The polymers are soluble, but stable only up to 200—300°C. 

Jippliance wires require a higher temperature rating (105°C or higher). Therefore, the insulation is made of duorinated thermoplastics, such as poly-tetrafluoroethylene (PTEE) or duorinated ethylene—propjdene (EEP). 

Electrical Properties. AH polyolefins have low dielectric constants and can be used as insulators in particular, PMP has the lowest dielectric constant among all synthetic resins. As a result, PMP has excellent dielectric properties and alow dielectric loss factor, surpassing those of other polyolefin resins and polytetrafluoroethylene (Teflon). These properties remain nearly constant over a wide temperature range. The dielectric characteristics of poly(vinylcyclohexane) are especially attractive its dielectric loss remains constant between —180 and 160°C, which makes it a prospective high frequency dielectric material of high thermal stabiUty. 

Commonly used materials for cable insulation are poly(vinyl chloride) (PVC) compounds, polyamides, polyethylenes, polypropylenes, polyurethanes, and fluoropolymers. PVC compounds possess high dielectric and mechanical strength, flexibiUty, and resistance to flame, water, and abrasion. Polyethylene and polypropylene are used for high speed appHcations that require a low dielectric constant and low loss tangent. At low temperatures, these materials are stiff but bendable without breaking. They are also resistant to moisture, chemical attack, heat, and abrasion. Table 14 gives the mechanical and electrical properties of materials used for cable insulation. 

Fig. 11. Crimp terminal contigurations (a) straight battel, 90° tongue, where wine without insulation is crimped in the battel, (b) Open battel having insulation-piercing lances, (c) Nylon or poly(vinyl chloride) preinsulated terminal accommodating and supporting wine insulation. Wine without end insulation is insetted in the terminal and is crimped. The terminal sleeve is not broken but conforms to the shape of the crimp indent, (d) Quick disconnect...

Nylon and poly(vinyl chloride) sleevings ate used for preinsulated terminals. Ceramics (qv) ate employed in some high voltage power connectors. Hard mbbet shells insulate connectors that serve underground power distribution cables. 

In all cases of electrochemicaHy or chemically polymerized unsubstituted polypyrrole, the final polymer is intractable in both the conducting and insulating forms. In contrast, a broad number of substituted polythiophenes have been found to be processible both from solution and in the melt. The most studied of these systems ate the poly(3-alkylthiophenes) (P3AT). 

Industrial equipment is a continuing area of development for plastics. Pipes, pumps, valves and sight glasses, made from such materials as PVC, PTFE and poly-4-methylpent-l-ene, have become well established on account of their corrosion resistance. The nylons are used for such diverse applications as mine conveyor belts and main drive gears for knitting machines and paper-making equipment. These and other materials are widely used where such features as toughness, abrasion resistance, corrosion resistance, non-stick properties, electrical insulation capability and transparency are of importance. 

When dipoles are directly attached to the chain their movement will obviously depend on the ability of chain segments to move. Thus the dipole polarisation effect will be much less below the glass transition temperature, than above it Figure 6.4). For this reason unplasticised PVC, poly(ethylene terephthalate) and the bis-phenol A polycarbonates are better high-frequency insulators at room temperature, which is below the glass temperature of each of these polymers, than would be expected in polymers of similar polarity but with the polar groups in the side chains. 

In the case of polymer molecules where the dipoles are not directly attached to the main chain, segmental movement of the chain is not essential for dipole polarisation and dipole movement is possible at temperatures below the glass transition temperature. Such materials are less effective as electrical insulators at temperatures in the glassy range. With many of these polymers, e.g., poly(methyl methacrylate), there are two or more maxima in the power factor-temperature curve for a given frequency. The presence of two such maxima is due to the different orientation times of the dipoles with and without associated segmental motion of the main chain. 

Poly(vinyl chloride) has a good resistance to hydrocarbons but some plasticisers, particularly the less polar ones such as dibutyl sebacate, are extracted by materials such as iso-octane. The polymer is also resistant to most aqueous solutions, including those of alkalis and dilute mineral acids. Below the second order transition temperature, poly(vinyl chloride) compounds are reasonably good electrical insulators over a wide range of frequencies but above the second order transition temperature their value as an insulator is limited to low-frequency applications. The more plasticiser present, the lower the volume resistivity. 

Poly(methyl methacrylate) is a good electrical insulator for low-frequency work, but is inferior to such polymers as polyethylene and polystyrene, particularly at high frequencies. The influence of temperature and frequency on the dielectric constant is shown in Figure 15.9. 

The use of ABS has in recent years met considerable competition on two fronts, particularly in automotive applications. For lower cost applications, where demands of finish and heat resistance are not too severe, blends of polypropylene and ethylene-propylene rubbers have found application (see Chapters 11 and 31). On the other hand, where enhanced heat resistance and surface hardness are required in conjunction with excellent impact properties, polycarbonate-ABS alloys (see Section 20.8) have found many applications. These materials have also replaced ABS in a number of electrical fittings and housings for business and domestic applications. Where improved heat distortion temperature and good electrical insulation properties (including tracking resistance) are important, then ABS may be replaced by poly(butylene terephthalate). 

Although it is a polar polymer, its electrical insulating properties at room temperature are good even at high frequencies owing to the fact that since room temperature is well below the transition temperature dipole orientation is severely restricted. Some data on the crystallinity of poly(ethylene terephthalate) are presented in Table 25.5. 

---