101A083-100/180-0 (795955-001) - Tyco Electronics

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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® Zerohal™ 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

121°C (250°F).

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 Hydraulic Fluid, Petroleum Base, Aircraft, Missile and Ordnance

MIL-T-5624 Turbine Fuel, Aviation, Grades JP-4 and JP-5

MIL-L-23699 Lubricating Oil, Aircraft Turbine Engine, Synthetic Base

MIL-C-24643 Cable and Cord, Electrical, Low Smoke, for Shipboard Use, General Specification for

2.2 OTHER PUBLICATIONS

American Society for Testing and Materials (ASTM)

D 149 Standard Methods of Test for Dielectric Breakdown Voltage and Dielectric Strength of

Electrical Insulating Materials at Commercial Power Frequencies

D 257 Standard Methods of Test for D-C Resistance or Conductance of Insulating Materials

D 412 Standard Test Method for Rubber Properties in Tension

D 570 Standard Methods of Test for Water Absorption of Plastics

D 635 Standard Methods of Test for Rate of Burning and/or Extent and Time of Burning of Self-

Supporting Plastics in a Horizontal Position

D 792 Standard Methods of Test for Specific Gravity and Density of Plastics by Displacement

D 882 Standard Test Methods for Tensile Properties of Thin Plastic Specimens

D 2671 Standard Methods of Testing Heat-Shrinkable Tubing for Electrical Use

D 2863 Standard Method for Measuring the Minimum Oxygen Concentration to Support Candle-

Like Combustion of Plastics (Oxygen Index)

D 3487 Specification for Mineral Insulating Oil Used in Electrical Apparatus

E 662 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.)

Page 2 SPECIFICATION RT-1323 ISSUE 1

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3. REQUIREMENTS

3.1 MATERIAL

The molded components shall be fabricated from a crosslinked, halogen- free, thermally stabilized, flame-

retarded, 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. QUALITY ASSURANCE PROVISIONS

4.1 CLASSIFICATION OF TESTS

4.1.1 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 SAMPLING INSTRUCTIONS

4.2.1 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 TEST PROCEDURES

4.3.1 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 ± 4°F) 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.

SPECIFICATION RT-1323 ISSUE 1 Page 3

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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 ± 2°C (-4 ± 4°F) 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

± 5°C (437 ± 9°F) 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 ± 3°C (302 ± 5°F) 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 ± 2°C (± 4°F).

With the gas supply regulated to 21% oxygen content, determine the temperature, within 10°C (18°F), 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. PREPARATION FOR DELIVERY

5.1 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.

Page 4 SPECIFICATION RT-1323 ISSUE 1

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TABLE 1

Requirements

PROPERTY UNIT REQUIREMENT TEST METHOD

PHYSICAL

Dimensions

in (mm)

In accordance with applicable

specification control drawing.

Sec. 4.3.1

Dimensional Recovery in (mm) In accordance with applicable

specification control drawing.

Tensile Strength, min. psi (MPa) 1000 minimum (7) Sec. 4.3.2

Ultimate Elongation, min. Percent 250 minimum ASTM D 412

Secant Modulus at 2% Strain psi (MPa) 7250-17400 (50-120) Sec. 4.3.3

ASTM D 882

Specific Gravity --- 1.5 maximum ASTM D 792

Low Temperature Flexibility

4 hours at -20°C (-4°F)

--- No cracking Sec. 4.3.4

Heat Shock

4 hours at 225°C (437°F)

--- No dripping, flowing or cracking Sec. 4.3.5

Heat Aging

168 hr. at 150°C (302°F)

Followed by tests for:

--- --- Sec. 4.3.6

Tensile Strength psi (MPa) 1000 minimum (7)

Ultimate Elongation Percent 100 minimum

ELECTRICAL

Dielectric Strength

V/mil (kV/mm)

380 minimum (15)

ASTM D 149

Short time test

Volume Resistivity ohm-cm 1012 minimum ASTM D 257

CHEMICAL

Water Absorption

24 hours at 23°C (73°F)

24 hours at 70°C (158°F)

Percent

0.5 maximum

1.5 maximum

ASTM D 570

Limiting Oxygen Index Percent 30 minimum ASTM D 2863

Oxygen Index

at Elevated Temperature

°C 250minimum Sec. 4.3.8

Flammability

Average Time of Burning

Average.Extent of Burning

seconds

in (mm)

100 maximum

1 maximum (25)

ASTM D 635

Smoke Density, Ds

4 minutes, flaming mode

--- 60 maximum ASTM E 662

Acid Gas Generation

HCl Equivalent

Percent 1.5 maximum MIL-C-24643

SPECIFICATION RT-1323 ISSUE 1 Page 5

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TABLE 1

Requirements

PROPERTY UNIT REQUIREMENT TEST METHOD

CHEMICAL (continued)

Fluid Resistance

24 hours at 23°C (73°F)

Hydraulic Fluid (MIL-H-5606)

JP-4 Fuel (MIL-T-5624)

*Skydrol 500

Hydraulic Fluid

ASTM Fuel B

Water

---

Sec. 4.3.7

24 hours at 50°C (122°F)

Lube Oil (MIL-L-23699)

Insulating Oil (ASTM D 3487)

24 hours at 100°C (212°F)

ASTM #2 Oil

Followed by tests for:

Tensile Strength psi (MPa) 725 minimum (5)

Ultimate Elongation Percent 150 minimum

*TM Monsanto Co.