Tyco Electronics Corporation 300 Constitutional Drive Menlo Park, CA 94025 USA Specification This Issue: Date: Replaces: RT-1323 Issue 1 August 5, 1986 None Thermofit(R) ZerohalTM Polyolefin Molded Components Halogen-Free, Flame Retarded, Semi-Flexible, Heat-Shrinkable 1. SCOPE This specification covers the requirements for one type of semi-flexible electrical insulating molded component whose dimensions will reduce to a predetermined size upon the application of heat in excess of 121C (250F). 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-H-5606 MIL-T-5624 MIL-L-23699 MIL-C-24643 2.2 Hydraulic Fluid, Petroleum Base, Aircraft, Missile and Ordnance Turbine Fuel, Aviation, Grades JP-4 and JP-5 Lubricating Oil, Aircraft Turbine Engine, Synthetic Base Cable and Cord, Electrical, Low Smoke, for Shipboard Use, General Specification for OTHER PUBLICATIONS American Society for Testing and Materials (ASTM) D 149 D 257 D 412 D 570 D 635 D 792 D 882 D 2671 D 2863 D 3487 E 662 Standard Methods of Test 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 Materials Standard Test Method 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 SelfSupporting Plastics in a Horizontal Position Standard Methods of Test for Specific Gravity and Density of Plastics by Displacement Standard Test Methods for Tensile Properties of Thin Plastic Specimens Standard Methods of Testing Heat-Shrinkable Tubing for Electrical Use Standard Method for Measuring the Minimum Oxygen Concentration to Support CandleLike Combustion of Plastics (Oxygen Index) Specification for Mineral Insulating Oil Used in Electrical Apparatus Test Method for Specific Optical Density of Smoke Generated by Solid Materials (Copies of ASTM publications may be obtained from the American Society for Testing and Materials, 1916 Race Street, Philadelphia, Pennsylvania 19103.) If this document is printed it becomes uncontrolled. Check for the latest revision. Page 2 SPECIFICATION RT-1323 ISSUE 1 3. 3.1 REQUIREMENTS MATERIAL The molded components shall be fabricated from a crosslinked, halogen- free, thermally stabilized, flameretarded, modified polyolefin composition. They shall be homogeneous and essentially free from flaws, defects, pinholes, bubbles, seams, cracks, and inclusions. 3.2 COLOR The molded components shall be black, unless otherwise specified. 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: dimensions, dimensional recovery, tensile strength, ultimate elongation, secant modulus, specific gravity and dielectric strength. 4.2 4.2.1 SAMPLING INSTRUCTIONS Qualification Test Samples Qualification test samples shall consist of molded slabs, 6 x 6 x 0.075 0.010 inches (152 x 152 x 1.9 .25 mm) 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. 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 2C (302 4F) oven or equivalent, cooled to room temperature, and remeasured. 4.3.2 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. 4.3.3 Secant Modulus Five specimens, 6 x 3/4 x 0.075 inches (150 x 19 x 1.9 mm) cut from a molded slab shall be tested for secant modulus at two percent strain in accordance with ASTM D 882. Use an initial jaw separation of 4 inches (100 mm) and a crosshead speed of 0.4 inches (10 mm) per minute. If this document is printed it becomes uncontrolled. Check for the latest revision. SPECIFICATION RT-1323 ISSUE 1 Page 3 4.3.4 Low Temperature Flexibility Three 6 x 1/4 inch (152 x 6.3 mm) specimens cut from a slab shall be conditioned, along with a 3-inch (75-mm) mandrel, in a cold chamber at -20 2C (-4 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 less than 360 degrees 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 5C (437 9F) mechanical convection oven with an air velocity of 100 to 200 feet (30 to 60 m) per minute past the specimens. After conditioning, the specimens shall be removed from the oven, cooled to room temperature, and 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 4.3.2, shall be conditioned for 168 hours in a 150 3C (302 5F) mechanical convection oven in which air passes the specimens at a velocity of 100 to 200 feet (30 to 60 m) per minute. 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 4.3.2. 4.3.7 Fluid Resistance Three specimens prepared in accordance with 4.3.2, shall be completely immersed in each of the fluids listed in the applicable section of Table 1 for 24 hours at the specified temperature. 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 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 4.3.2. 4.3.8 Oxygen Index at Elevated Temperature Determine the oxygen index using the apparatus described in ASTM D 2863 with the exception of a special double wall glass chimney replacing the standard chimney. This chimney must be equipped with a heating element and temperature controller capable of maintaining the temperature of the gas atmosphere in the chimney to 2C ( 4F). With the gas supply regulated to 21% oxygen content, determine the temperature, within 10C (18F), at which the specimen will burn 3 minutes or 2 inches (50 mm), whichever occurs first, using the endpoint criteria of ASTM D 2863. Report this temperature as the oxygen index at elevated temperature. 4.4 REJECTION AND RETEST Failure of any samples 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 If not specified, packaging of molded components shall be in accordance with good commercial practice. The exterior shipping container shall be not less than 125 pound-test fiberboard. 5.2 MARKING Each molded component shall be distinctly identified on the part and/or package with the manufacturer's name or symbol, the manufacturer's part number, and lot number. If this document is printed it becomes uncontrolled. Check for the latest revision. Page 4 SPECIFICATION RT-1323 ISSUE 1 TABLE 1 Requirements PROPERTY PHYSICAL Dimensions UNIT REQUIREMENT TEST METHOD in (mm) Sec. 4.3.1 Dimensional Recovery in (mm) Tensile Strength, min. Ultimate Elongation, min. Secant Modulus at 2% Strain psi (MPa) Percent psi (MPa) In accordance with applicable specification control drawing. In accordance with applicable specification control drawing. 1000 minimum (7) 250 minimum 7250-17400 (50-120) Specific Gravity Low Temperature Flexibility 4 hours at -20C (-4F) Heat Shock 4 hours at 225C (437F) Heat Aging 168 hr. at 150C (302F) Followed by tests for: Tensile Strength Ultimate Elongation ELECTRICAL Dielectric Strength ----- 1.5 maximum No cracking Sec. 4.3.2 ASTM D 412 Sec. 4.3.3 ASTM D 882 ASTM D 792 Sec. 4.3.4 --- No dripping, flowing or cracking Sec. 4.3.5 --- --- Sec. 4.3.6 psi (MPa) Percent 1000 minimum (7) 100 minimum V/mil (kV/mm) 380 minimum (15) ohm-cm 1012 minimum Volume Resistivity CHEMICAL Water Absorption 24 hours at 23C (73F) 24 hours at 70C (158F) Limiting Oxygen Index Oxygen Index at Elevated Temperature Flammability Average Time of Burning Average.Extent of Burning Smoke Density, Ds 4 minutes, flaming mode Acid Gas Generation HCl Equivalent Percent ASTM D 149 Short time test ASTM D 257 ASTM D 570 Percent C 0.5 maximum 1.5 maximum 30 minimum 250minimum seconds in (mm) --- 100 maximum 1 maximum (25) 60 maximum ASTM E 662 Percent 1.5 maximum MIL-C-24643 ASTM D 2863 Sec. 4.3.8 ASTM D 635 If this document is printed it becomes uncontrolled. Check for the latest revision. SPECIFICATION RT-1323 ISSUE 1 Page 5 TABLE 1 Requirements PROPERTY CHEMICAL (continued) Fluid Resistance 24 hours at 23C (73F) Hydraulic Fluid (MIL-H-5606) JP-4 Fuel (MIL-T-5624) *Skydrol 500 Hydraulic Fluid ASTM Fuel B Water 24 hours at 50C (122F) Lube Oil (MIL-L-23699) Insulating Oil (ASTM D 3487) 24 hours at 100C (212F) ASTM #2 Oil Followed by tests for: Tensile Strength Ultimate Elongation UNIT REQUIREMENT TEST METHOD --- --- Sec. 4.3.7 psi (MPa) Percent 725 minimum (5) 150 minimum *TM Monsanto Co. If this document is printed it becomes uncontrolled. Check for the latest revision.