Tyco Electronics Corporation 300 Constitutional Drive Menlo Park, CA 94025 USA Specification This Issue: Date: Replaces: RT-1304 Issue 3 April 17, 1995 Issue 2 Thermofit(R) Polyolefin Molded Components Flame-Retarded. Flexible, Heat-Shrinkable 1. SCOPE This specification covers the requirements for one type of flexible, electrical insulating molded component whose expanded dimensions will reduce to a predetermined size upon the application of heat in excess of 100C (212F). 2. APPLICABLE DOCUMENTS This specification takes precedence over documents referenced herein. Unless otherwise specified, the latest issue of referenced documents applies. The following documents form a part of this specification to the extent specified herein. 2.1 GOVERNMENT-FURNISHED DOCUMENTS Military MIL-G-5572 Gasoline, Aviation, Grades 80/87, 100/130, 115/145 MIL-H-5606 Hydraulic Fluid, Petroleum Base, Aircraft, Missile and Ordnance MIL-T-5624 Turbine Fuel, Aviation, Grades JP-4 and JP-5 MIL-STD-105 Sampling Procedures and Tables for Inspection by Attributes 2.2 OTHER PUBLICATIONS American Society for Testing and Materials (ASTM) D 149 D 747 Standard Methods of Tests for Dielectric Breakdown Voltage and Dielectric Strength of Electrical Insulating Materials at Commercial Power Frequencies Standard Methods of Test for D-C Resistance or Conductance of Insulating Material. Standard Method of Tests for Rubber Properties in Tension Standard Methods of Test for Water Absorption of Plastics Standard Methods of Test for Rate of Burning and/or Extent and Time of Burning of Self-Supporting Plastics in a Horizontal Position Standard Methods of Test for Stiffness of Plastics by Means of a Cantilever Beam D 792 Standard Methods of Test for Specific Gravity and Density of Plastics by Displacement D 257 D 412 D 570 D 635 D 2240 Standard Method of Tests for Rubber Property-Durometer Hardness D 2671 Standard Methods of Testing Heat Shrinkable Tubing for Electrical Use G 21 Recommended Practice for Determining Resistance of Synthetic Polymeric Materials to Fungi (Copies of ASTM Publications may be obtained from the American Society for Testing and Materials, 1916 Race Street, Philadelphia, Pennsylvania 19103.) 3. 3.1 REQUIREMENTS MATERIAL The molded components shall be fabricated from a crosslinked, thermally stabilized, flame resistant, modified polyolefin composition. They shall be homogeneous and essentially free from flaws, defects, pinholes, bubbles, seams, cracks, and inclusions. If this document is printed it becomes uncontrolled. Check for the latest revision. Page 2 SPECIFICATION RT-1304 ISSUE 3 3.2 COLOR The molded components shall be black. 3.3 PROPERTIES The molded components and the material from which they are fabricated shall meet the requirements of Table 1. 4. 4.1 4.1.1 QUALITY ASSURANCE PROVISIONS CLASSIFICATION OF TESTS Qualification Tests Qualification tests are those performed on molded slabs and components submitted for qualification as satisfactory products and shall consist of all tests listed in this specification. 4.1 .2 Acceptance Tests Acceptance tests are those performed on molded slabs and components submitted for acceptance under contract. Acceptance tests shall consist of the following: dimensional recovery, tensile strength, ultimate elongation, heat shock, and flammability. 4.2 4 2.1 SAMPLING INSTRUCTIONS Qualification Test Samples Qualification test samples shall consist of six molded slabs, 6 x 6 x 0.075 + 0.010 inches (152 x 152 x 1.9 + .25mm) and the number of molded components specified. The molded slabs shall be fabricated from the same lot of material and shall be subjected to the same degree of crosslinking as the molded components. 4.2.2 Acceptance Test Samples Acceptance test samples shall consist of specimens cut from a molded slab 6 x 6 x 0.075 + 0.010 inches (152 x 152 x 1.9 + .25 mm), and molded components selected at random in accordance with MIL-STD105, Inspection Level S-2, AQL 6.5 percent. The molded slab shall be fabricated from the same lot of material and shall be subjected to the same degree of crosslinking as the molded components. A lot of components shall consist of all molded components from the same lot of material, from the same production run, and offered for inspection at the same time. 4.3 4.3.1 TEST PROCEDURES Dimensional Recovery Samples of molded components, as supplied, shall be measured for dimensions in accordance with ASTM D 2671. The samples then shall be conditioned for 10 minutes in a 150 + 2 C (302 + 4F) oven, or equivalent, cooled to room temperature and remeasured. 4.3.2 Elastic Memory A 6 x 1/8-inch (152 x 3.2-mm) specimen cut from a molded slab shall be marked with two parallel gage lines 1 inch (25 mm) apart in the central portion of the specimen. The distance between gage lines shall be recorded as the original length. A 2-inch (51-mm) portion of the specimen including both gage lines then shall be heated for 1 minute in a 150 + 2C (302 + 4F) oven, or equivalent, removed from the oven and stretched within 10 seconds, until the gage lines are 4 inches (102 mm) apart. The extended specimen shall be cooled to room temperature and released from tension. After 24 hours at room temperature, the distance between the gage lines shall be measured and recorded as the extended length. The portion of the specimen including both gage lines then shall be reheated for 1 minute in a 150 + 2 C (302 + 4F) oven, or equivalent, and the distance between gage lines then shall be measured and recorded as the retracted length. If this document is printed it becomes uncontrolled. Check for the latest revision. SPECIFICATION RT-1304 ISSUE 3 Page 3 Expansion and retraction shall be calculated as follows: E = R = Where: L e- Lo Lo x 100 L e - Lr Le - Lo x 100 E = Expansion (percent) R = Retraction (percent) Lo= Original Length (inches) (mm) Le= Extended Length inches (mm) Lr = Retracted Length (inches) (mm) 4.3.3 Tensile Strength and Ultimate Elongation Three specimens cut from a molded slab using Die D of ASTM D 412 shall be tested for tensile strength and ultimate elongation in accordance with ASTM D 412. 4.3.4 Low Temperature Flexibility Three 6 x 1/4-inch (152 x 6.3-mm) specimens cut from a molded slab shall be conditioned, along with a 3/8-inch (9.5-mm) mandrel, in a cold chamber at -55 + 2C (-67 + 4F) for 4 hours. After completion of the conditioning, and while still in the cold chamber, each specimen shall be bent around the mandrel through not tess than 360 degrees (6.28 rads) within 10 + 2 seconds. The specimens then shall be visually examined for cracks. 4.3.5 Heat Shock Three 6 x 1/4-inch (152 x 6.3-mm) specimens cut from a molded slab shall be conditioned for 4 hours in a 225 + 5 C (437 + 9F) mechanical convection oven with an air velocity of from 100 to 200 feet per minute past the specimens. After conditioning, the specimens shall be removed from the oven, cooled to room temperature, and bent through 360 degrees (6.38 rads) over a 3/8-inch (9.5-mm) diameter mandrel. The specimens then shall be visually examined for evidence of dripping, flowing or cracking. 4.3.6 Heat Aging Three specimens, prepared and measured in accordance with 4.3.3 shall be conditioned for 168 hours in a 175 + 5 C (347 + 9F) mechanical convection oven with an air velocity of 100 to 200 feet per minute past the specimens. After conditioning, the specimens shall be removed from the oven, cooled to room temperature, and tested for tensile strength and ultimate elongation in accordance with 4.3.3. 4.3.7 Corrosive Effect Three 1 x 1/4-inch (25.4 x 6.3-mm) specimens cut from a molded slab shall be tested for corrosive effect in accordance with ASTM D 2671, Procedure A. The specimens shall be conditioned for 16 hours at 175 + 3C (347 + 5F). 4.3.8 Fluid Resistance Three specimens prepared and measured in accordance with 4.3.3 shall be completely immersed in each of the test fluids listed in Table I for 24 hours at 25 + 3 C (77 + 5 F). The volume of the fluid shall be not less than 20 times that of the specimens. After conditioning, the specimens shall be lightly wiped and then air-dried for 30 to 60 minutes at room temperature. The specimens then shall be tested for tensile strength and ultimate elongation in accordance with 4.3 .3. If this document is printed it becomes uncontrolled. Check for the latest revision. Page 4 SPECIFICATION RT-1304 ISSUE 3 4.4 REJECTION AND RETEST Failure of any sample to comply with any one of the requirements of this specification shall be cause for rejection of the lot represented. Material which has been rejected may be replaced or reworked to correct the defect and then resubmitted for acceptance. Before resubmitting, full particulars concerning the rejection and the action taken to correct the defect shall be furnished to the inspector. 5. 5. 1 PREPARATION FOR DELIVERY PACKAGING Packaging of molded components shall be in accordance with good commercial practice. The shipping container shall be not less than 125 pound test fiberboard. 5.2 MARKING Each molded component shall be distinctly identified with the manufacturing name or symbol and the manufacturers part number. If this document is printed it becomes uncontrolled. Check for the latest revision. SPECIFICATION RT-1304 ISSUE 3 Page 5 TABLE 1 Requirements PROPERTY PHYSICAL Dimensions UNIT REQUIREMENTS TEST METHOD Inches (mm) Section 4.3.1 ASTM D 2671 Dimensional Recovery Inches (mm) Elastic Memory Percent Tensile Strength Ultimate Elongation Stiffness Specific Gravity Hardness Low Temperature Flexibility 4 hours at -55C (-67F) Heat Shock 4 hours at 225C (437F) Heat Aging 168hours at 175C (347F) Followed by tests for: Tensile Strength Ultimate Elongation ELECTRICAL Dielectric Strength psi (MPa) Percent psi (MPa) --Shore D --- In accordance with applicable specification control drawing In accordance with applicable specification control drawing 275 minimum expansion 93 minimum retraction 1200 minimum (8.27) 250 minimum 10,000 maximum (68.9) 1.40 maximum 40 5 No cracking Section 4.3.3 ASTM D 412 ASTM D 747 ASTM D 792 ASTM D 2240 Section 4.3.4 --- No dripping, flowing o cracking. Section 4.3.5 --- --- Section 4.3.6 psi (MPa) Percent 1000 minimum (6.89) 200 minimum Section 4.3.3 Volts/mil (kV/mm) ohm-cm 225 minimum (8.9) ASTM D 149 1012 minimum ASTM D 257 --- Non corrosive Section 4.3.7 ASTM D 2671 Procedure A ASTM D 635 Seconds Inches (mm) --- 120 maximum 1 maximum (25) Rating of 1 or less ASTM G 21 Percent --- 0.5 maximum --- ASTM D 570 Section 4.3.8 psi (MPa) Percent 750 minimum (5.22) 200 minimum Section 4.3.3 Volume Resistivity CHEMICAL Corrosive Effect 16 hours at 175C (347F) Flammability Average Time of Burning Average Extent of Burning Fungus Resistance Water Absorption 24 hours at 23C (73F) Fluid Resistance 24 hours at 23C (73F) in: JP-4 Fuel (MIL-T-5624) Skydrol* 500 Hydraulic Fluid (MIL-H-5606) Aviation Gasoline (100/130) (MIL-G-5572) Water Followed by tests for: Tensile Strength Ultimate Elongation *Trademark of the Monsanto Company. If this document is printed it becomes uncontrolled. Check for the latest revision. Section 4.3.2