Beyond wire & cable
Numerous industries & applications can benefit from NanoSync's solutions beyond wire & cable. NanoSync's technology suite can provide existing compounds with alternatives for low hazard, fire retardant and gas barrier properties. Solutions of that grade could be implemented in Wood Plastic Composites (WPC), recycled plastics, termoplastic polyurethane, PET & PBT, biopolymers, ABS & TPE.
NanoSync's technology suite can find application in improving the quality of extruded compounds like synthetic and natural rubber where surface scorch problems could be mitigated and higher curing speed achieved. The halogenated compounds like soft PVC could be improved and the replacement of toxic ATO provided.
NanoSync's technology suite creates new opportunities for compounds where limited fire retardant solutions exist novadays like polyamides and polyesters.
Examples & Case studies
Alternative Low Voltage Unipolar Power Cable Design
OBJECTIVES
The key objective is to pass the bundle fire test IEC 60332-3
POPULAR SOLUTIONS TO DATE AND IDENTIFIED PROBLEMS
Solution 1
Cu \ Synthetic rubber \ Bedding compound \ Standard HFFR compound with LOI 35
Cu \ Synthetic rubber \ HFFR compound with LOI above 40 with high filler loading
Solutions characterised above use to pass the bundle test but are more expensive and more time consuming than if using NanoSync compounds and masterbatches
Solution 2
Cu \ XLPE \ HFFR compound with LOI above 40 with high filler loading
This solution does not pass the bundle test even with high filler loading and subsequent very high LOI value. Note that XLPE is less flame retardant than synthetic rubber.
SOLUTION BY NANOSYNC
NanoSync proposed to apply flame retardand compound with extremely good char forming properties and flame retardancy level 3 or 4.
The resulting, new cable construction is:
Cu \ XLPE \ NanoSync jacketing HFFR compound
This cable passes bundle fire test IEC 60332-3
NanoSync compound allows cable design simplification and cost reduction
High Performance Fire Resistant Cable with Silicone Rubber Insulation
OBJECTIVES
The key objective is to pass EN50200/BS 8434 test for unprotected small electric cables for use in emergency circuits, with addition of water spray.
POPULAR SOLUTIONS TO DATE AND IDENTIFIED PROBLEMS
Cu / Mica tape / XLPE / HFFR Bedding / Metallic foil / HFFR Outer Sheath with LOI 35 or flame retardancy level 0
SOLUTION BY NANOSYNC
NanoSync proposed to apply flame retardand compound with extremely good char forming properties and flame retardancy level 3 or 4.
The resulting, new cable construction is:
Construction 1
Cu / Insulation / Metallic foil / NanoSync jacketing HFFR compound, flame retardancy level 3 or 4 with insulation made out of ceramifiable silicone rubber
Construction 2
Cu / Mica Tape / Insulation / Metallic foil/ Nanosync HFFR compound, flame retardancy level 1 or 2 with insulation made out of crosslinked polyolefin
NanoSync's HFFR compounds allow for savings in materials’ consumption, f.ex.: mica tape, metallic foil’s thickness as well as reduction of cable weight. NanoSync’s HFFR compounds will protect the metallic foil and prevent water from reaching the conductor.
Flexible Flame Retardant Cable
OBJECTIVES
The key objective is to improve the flame retardancy and mechanical resistance of flexible LV cables used for various appliances, just like H03/H05 Z1Z1 used for refrigerators, washing machines, vacuum cleaners, etc.
POPULAR SOLUTIONS TO DATE AND IDENTIFIED PROBLEMS
The popular solution is the application of soft PVC compounds due to their high flexibility observed both in insulation and outer sheath of cables.
Nevertheless, PVC generate highly toxic, corrosive gases and produce high levels of smoke during exposure to fire. The alternative use of HFFR compounds allow to pass IEC 60332-1-2/EN 50265 flame retardancy tests but rarely the alternating bending test according to VDE 0472 standard part 603 requiring 30.000 cycles per minute, without cracks appearing on the outer sheath.
SOLUTION BY NANOSYNC
NanoSync proposed to apply flame retardand compound with the flame retardancy level 2, applied as an outer sheath which allows flexible H03/H05 Z1Z1 cables to pass both severe flame retardancy and bending tests, even when the insulation is made out of LDPE which is generally not flame retardant material.
This approach grants lower cable weight, safer and more cost efficient cable construction.