The Global Cable Industry: Materials, Markets, Products

407 Pages·2021·15.825 MB·English

by  Günter Beyer (editor)

TheGlobalCableIndustry
The Global Cable Industry
Materials,Markets,Products
Editedby
GünterBeyer
Editor AllbookspublishedbyWiley-VCH
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v
Contents
AbouttheEditor xv
1 OverviewoftheGlobalCableIndustry–Marketsand
Materials 1
AstridAupetit
1.1 DemandforPolymericMaterial 3
1.1.1 MainCompaniesProfile 3
1.1.1.1 Prysmian 4
1.1.1.2 Nexans 4
1.1.1.3 Southwire 5
1.1.1.4 SumitomoElectricIndustries 5
1.1.1.5 FurukawaElectricCo.,Ltd. 5
1.1.1.6 LSCable&System 6
1.1.1.7 LeoniAG 6
1.1.1.8 HengtongGroup 6
1.1.2 GlobalDemand 7
1.2 AsiaandAustralasia 10
1.2.1 DemandforCable 10
1.2.2 DemandforPolymericMaterial 11
1.3 Europe 12
1.3.1 DemandforCables 12
1.3.2 DemandforPolymericMaterials 13
1.4 TheMiddleEastandAfrica 14
1.4.1 DemandforCables 14
1.4.2 DemandforPolymericMaterials 14
1.5 NorthAmerica 16
1.5.1 DemandforCables 16
1.5.2 DemandforPolymericMaterials 17
1.6 SouthandCentralAmerica 18
1.6.1 DemandforCables 18
1.6.2 DemandforPolymericMaterials 19
vi Contents
2 ThermoplasticsforCables 21
TheoGeussens
2.1 Introduction 21
2.2 PolyolefinMaterials 21
2.2.1 Polyethylene 22
2.2.1.1 ManufacturingProcesses 25
2.2.1.2 CableApplications 26
2.2.2 Polypropylene(PP) 32
2.2.2.1 ManufacturingProcesses 33
2.2.2.2 Applications 33
2.3 ChlorinatedPolymers 35
2.3.1 Polyvinylchloride(PVC) 35
2.3.2 ChlorinatedPolyethylene(CPE) 36
2.4 Fluoropolymers 37
2.4.1 Fluoro-EthylenePropylenepolymer 37
2.4.2 Polytetrafluoroethylene(PTFE),EthyleneTetrafluoroethylene(ETFE),
andPerfluoroalkoxyPolymer(PFA) 38
2.4.3 EthyleneChlorotrifluoroethylene(ECTFE) 40
2.4.4 Polyvinyldifluoride(PVDF) 40
2.5 Polyamide(PA) 40
2.6 Polyesters 41
2.6.1 Polybutylphtherephtalate(PBT) 41
2.6.2 PolyesterElastomers 41
2.7 ThermoplasticPolyurethane 42
References 43
3 ElastomersforCables 57
BurkhardHerpich
3.1 Introduction 57
3.2 RubberCompounds 63
3.2.1 Rubber 63
3.2.2 Fillers 66
3.2.3 Plasticizer 68
3.2.4 Stabilizers 70
3.2.5 ClassicalCross-linkingSystems 71
3.2.5.1 Cross-linkingwithSulfurSystems 71
3.2.5.2 Cross-linkingwithPeroxideSystems 71
3.2.5.3 MovingDieRheometers(MDRs) 72
3.2.6 OtherCross-linkingSystems 73
3.2.6.1 Cross-linkingbyIrradiation 73
3.2.6.2 Cross-linkingwithSilanes 73
3.3 Compounding 73
3.4 Extrusion 76
3.5 Cross-linking/Vulcanization 78
3.5.1 VulcanizationinSaturatedHotWaterSteam 78
3.5.2 VulcanizationinLiquidSaltMixturesunderPressure 80
3.5.3 ElectronBeamCross-linking 81
References 82
Contents vii
4 ExtrusionofCables 85
StéphanPuissant
4.1 HistoricalIntroductiontoCableExtrusion 85
4.2 ExtruderinCableLines 87
4.2.1 DescriptionoftheSingleScrewExtruder 87
4.2.1.1 DifferentFunctionalScrewZones 87
4.2.1.2 DescriptionofaScrewGeometry 88
4.2.2 FeedingZoneoftheExtrusionScrew 89
4.2.2.1 Friction-BasedFeedingMechanism 89
4.2.2.2 SimpleModelingoftheFeedingZone 90
4.2.2.3 ImprovementoftheFeedingZone:UseofHelicalGroovedBarrel 95
4.2.3 ThinFilmPlastification 97
4.2.3.1 MeltingontheBacksideofFlight 97
4.2.3.2 InitiationofLiquidFilm 98
4.2.3.3 MeltFlowRateintheLiquidFilm 99
4.2.3.4 InfluenceofDifferentParametersonMeltingLength 99
4.2.3.5 ThinFilmMeltingwiththeHelpofaBarrierZone 103
4.2.3.6 BarrierZone,ItsAdvantages,andItsDrawbacks 103
4.2.4 MeteringZone 104
4.2.4.1 RepresentationoftheMeteringZone 104
4.2.4.2 1DAnalysis 105
4.2.5 ExampleofResultsfor1DModelIncludingtheThreeZonesofthe
Screw 105
4.2.5.1 InfluenceofFrictionCoefficientsontheScrewCharacteristics 105
4.2.5.2 InteractionBetweenCompressionandFrictionintheFeeding
Zone 106
4.3 AccessoriesforExtruders 107
4.3.1 MixingZones 107
4.3.1.1 ObservedDefaults 107
4.3.1.2 DevicesSelectionCriteria 109
4.3.1.3 ExampleofResultsforFinatheneHDPE 111
4.3.2 MeltFiltrationSystems 113
4.3.3 MeltGearPumps 114
4.4 ExtrusionHeadsorDies 115
4.4.1 DescriptionoftheExtrusionHead 115
4.4.1.1 ExtrusionHeadFunction 115
4.4.2 Distributors 117
4.4.2.1 HeadwithCoatHangerTypeDistributionChannels 117
4.4.2.2 DistributionFunctionThroughFlattenedDistributionChannels 119
4.4.2.3 DistributorwithHelicalChannels 119
4.4.3 DiameterAdaptationFunction(Tooling) 119
4.4.3.1 TubeTooling,DDR 120
4.4.3.2 TubeTooling,DRB 121
4.4.4 RelationBetweenPressureandAverageTemperatureIncreaseinan
ExtrusionHead 121
4.5 Cooling 122
4.5.1 CoolingLengthAnalyticalCalculationforFineWires 122
viii Contents
4.5.2 CoolingLengthFiniteDifferenceCalculationforaWireofRadius
>1mmwithCopperCoreandPEInsulation 123
4.6 Quality 124
4.6.1 TheQualityParameterandItsMeasurement 124
4.6.1.1 DiameterandProductCircularityMeasurement 125
4.6.1.2 ConcentricityMeasurement 126
4.6.1.3 InsulationDefectsMeasurements(CableorWire) 126
4.6.1.4 CapacityMeasurement(TelecommunicationWire) 127
4.6.1.5 SheathingWallThicknessMeasurement 128
4.6.1.6 PeriodicityofMeasurementAnalysis 128
4.6.2 CommonProductionDefects,Causes,andRemedies 130
References 130
5 FoamExtrusion 133
HorstA.Scheid
5.1 Motivation 133
5.2 PhysicalBasics 133
5.3 SelectionofPolymer 136
5.4 SelectionofBlowingAgents 139
5.5 ExtrusionEquipment 141
5.5.1 ExtruderandScrew 143
5.5.2 DosingStation 145
5.5.3 GasInjection 145
5.5.4 MeltTransportfromScrewtoDie 148
5.5.5 CoolingTrough 149
5.5.6 MeasurementDevices 151
5.6 Processing 151
5.6.1 ExtrusionandDieSetup 152
5.6.2 ProcessControlModes 153
5.6.3 PBAHandling 154
5.6.4 MaximumVoidandBubbleSize 154
5.6.5 InlineAnalysisbyFFT 156
Glossary 157
References 158
6 FlameRetardancyofCables 161
GünterBeyer
6.1 Introduction 161
6.2 FlamePropagationTestsforWiresandCables 163
6.3 Smoke,Corrosivity,andToxicityTestsforWiresandCables 164
6.4 CircuitIntegrityandFunctionalIntegrityforSecurityCables 165
6.5 LaboratoryTestsfortheFlammabilityofWireandCable
Materials 167
6.6 PolymersforFlame-RetardantWiresandCables 167
6.7 FlameRetardantsforFlame-RetardantWiresandCables 168
6.8 Flame-RetardantPVC 169
Contents ix
6.8.1 FlameRetardantsforPVCandFlame-RetardantPVCCable
Formulations 169
6.8.1.1 Phthalate-BasedPlasticizersandOtherPlasticizers 169
6.8.1.2 AntimonyTrioxide 169
6.8.1.3 BrominatedPhthalatePlasticizers 170
6.8.1.4 ChlorinatedParaffins 171
6.8.1.5 AluminumHydroxide(ATH)andMagnesiumHydroxide(MDH) 171
6.8.1.6 ZincBorate 172
6.8.1.7 PhosphatePlasticizers 172
6.8.1.8 SmokeSuppressants 172
6.8.1.9 Nanocomposites 173
6.9 Flame-RetardantPolyolefins 174
6.9.1 FlameRetardantsforPolyolefinsandHFFRCableFormulations 175
6.9.1.1 AluminumHydroxide(ATH)andMagnesiumHydroxide(MDH) 175
6.9.1.2 ZincBorateandPolysiloxanes 176
6.9.1.3 Nanocomposites 176
6.9.1.4 CeramifiableCompounds 177
6.10 CPR(ConstructionProductsRegulation) 178
References 179
7 CPRTestingofCables 181
FranckPoutch
7.1 Introduction 181
7.2 FIPECProgram 182
7.2.1 FIPECApproach 183
7.2.1.1 Real-ScaleScenario 184
7.2.1.2 CableSelection 185
7.2.1.3 Real-ScaleFireTests 186
7.2.1.4 Full-ScaleFireTest 186
7.2.1.5 CapabilityStudy 188
7.2.1.6 CorrelationBetweenReal-andLarge-ScaleTest 189
7.3 ConstructionProductRegulation(CPR)Framework 190
7.3.1 EN13501-6 193
7.3.2 ENISO1716 196
7.3.3 EN60332-1-2 196
7.3.4 EN50399 198
7.3.5 ENISO61034-1(Apparatus)and-2(TestProcedure) 199
7.3.6 EN60754-2 201
References 206
7.A MeasuringHeatReleaseRate(HRR)byOxygenConsumption
Technique,andSmokeDensity 208
7.A.1 MeasureoftheHeatReleaseRate(HRR)byOxygenConsumption
Technique 208
7.A.1.1 BurningofMethane 208
7.A.1.2 DeterminationoftheMassFlowRate(ṁ ) 210
a
7.A.1.3 SmokeOpacity 211
7.A.1.4 CalculationofFIGRAandSMOGRAIndex 212
x Contents
8 CrosslinkingTechnologies 215
RonGoethals
8.1 Introduction 215
8.2 Crosslinking,Curing,Vulcanizing 216
8.3 CrosslinkingProcesses 217
8.4 TheSilane-CrosslinkingProcess 218
®
8.4.1 TheSioplas Process 218
®
8.4.2 TheMonosil Process 219
8.4.3 SilaneCopolymers 220
8.4.4 ReactivityoftheSilaneCrosslinkingProcess 220
8.4.5 AdvantagesandDisadvantagesofSilaneCrosslinking 221
8.5 ThePeroxideCrosslinkingProcess(CVCuring) 222
8.5.1 PolymerSelectionforPeroxideCrosslinking 223
8.5.2 AdvantagesandDisadvantagesofContinuousVulcanization
224
8.6 e-BeamCrosslinking 225
8.6.1 Awarenessofe-BeamsinOurDailyLife 225
8.6.2 ThePrincipleofane-Beam 227
8.6.3 CreatingaHighVoltagee-Beam 228
8.6.4 ScanHornandBeamWindow 228
8.6.5 Under-BeamHandlingSystem(UBHS) 229
8.6.6 ControlSystem 231
8.6.7 Safety 232
8.6.7.1 RadiationandRadioactivity 232
8.6.7.2 BremsstrahlungorX-rays 232
8.6.7.3 ShieldingandRadioactivity 233
8.6.7.4 OtherSafetySystems 234
8.6.7.5 Ozone 235
8.6.7.6 IAEA 235
8.6.8 MostImportantParametersDuringe-BeamCrosslinking
235
8.6.8.1 Voltage 235
8.6.8.2 Amperage 237
8.6.8.3 RadiationDose 237
8.6.9 Capacityofane-Beam 241
8.6.9.1 FunctionalCapacity 241
8.6.9.2 Efficiency 241
8.6.9.3 Dose 241
8.6.10 TemperatureRise 242
8.6.11 CompoundDesign 242
8.6.11.1 Polymers 242
8.6.12 CostsIndicationsofe-BeamCrosslinking 243
8.6.12.1 AnnualCosts 243
8.6.12.2 AnnualThroughputandCostsperKilograms 244
8.6.13 AdvantagesandDisadvantagesofe-BeamCrosslinking 244
8.7 Conclusions 245
FurtherReading 246