Most elevator cables are also silicone rubber high-temperature cables, which are suitable for elevators and lifting machinery and equipment with AC rated voltage of 300 / 500V (or 450 / 750V) and below. Nitrile silicone rubber high-temperature cables used as power connection wires are suitable for cranes, trolleys, vehicles with AC rated voltage of 0.6/1kv and below and special requirements for cold resistance, oil resistance, etc Power transmission lines and control, lighting and communication lines for mobile electrical appliances such as transmission machinery, and nitrile silicone rubber high-temperature cables have been widely used in metallurgy, electric power, ships, ports and other industries.
The silicon rubber high-temperature cable for traveling crane has the characteristics of cold resistance, softness, wear resistance and oil resistance. It is more suitable for traveling crane with AC rated voltage of 0.6/1kv and below. The split phase shielded nitrile flat cable with special requirements such as cold resistance and oil resistance is suitable for frequency converter power supply. The wear-resistant and anti-corrosion tensile silicon rubber high-temperature cable is suitable for power generation, metallurgy, chemical industry The electrical connection between mobile electrical equipment in harsh environment such as port has excellent wear-resistant, anti-corrosion, tensile resistance to high and low temperature and acid-base resistance.

As a common kind of special cable, silicone rubber high temperature cable is more widely used in various fields of industry due to its structure and shape. It mainly plays the role of power transmission. Most of the faults of flat cable are broken down due to reduced insulation. Chongqing wire and cable believes that there are many factors leading to insulation reduction. According to the actual operation experience, it can be summarized as follows.

This situation is also common in silicone rubber high temperature cables, which generally occurs at the flat cable joints in directly buried or row pipes. For example, the unqualified production of silicone rubber high-temperature cable joint and the making of silicone rubber high-temperature cable joint under humid climate conditions will make the joint water or mixed with water vapor. Over time, water branches will be formed under the action of electric field, which will gradually damage the insulation strength of silicone rubber high-temperature cable and cause failure.

According to the industry operation analysis in recent years, a considerable number of silicone rubber high-temperature cable faults are caused by mechanical damage. For example, the laying and installation of silicone rubber high-temperature cable is not standardized, which is easy to cause mechanical damage. Sometimes, if the damage is not serious, it will take months or even years to cause complete breakdown of the damaged part to form a fault. Sometimes, if the damage is serious, a short-circuit fault may occur in a short time, which will directly affect the operation of the equipment and the safety of the power user.

When the silicone rubber high-temperature cable is directly buried in the area with acid-base effect, the outer protective layer of the silicone rubber high-temperature cable is often corroded. The protective layer is subject to chemical corrosion or electrolytic corrosion for a long time, resulting in the failure of the protective layer, the reduction of insulation, and the failure of the silicone rubber high-temperature cable.

Silicone rubber high temperature cable joint failure. Silicone rubber high-temperature cable joint is a weak link in the cable line. Silicone rubber high-temperature cable joint faults caused by personnel's direct negligence (poor construction) often occur. In the process of making silicone rubber high-temperature cable joints, if there are reasons such as loose crimping and insufficient heating, the insulation of silicone rubber high-temperature cable head will be reduced, resulting in accidents.

Long term overload operation. During overload operation, due to the thermal effect of current, when the load current passes through the silicone rubber high-temperature cable, it will inevitably lead to conductor heating. At the same time, the skin effect of charge, eddy current loss of steel armor and insulation medium loss will also produce additional heat, so as to increase the temperature of silicone rubber high-temperature cable.

During long-term overload operation, too high temperature will accelerate the aging of insulation and even the insulation will be broken down. Especially in hot summer, the temperature rise of silicone rubber high-temperature cable often causes the weak insulation of silicone rubber high-temperature cable to be broken down first. Therefore, there are many faults of silicone rubber high-temperature cable in summer. Other reasons such as normal aging of flat cable itself or natural disasters, environment and temperature. The external environment and heat source of flat cable will also cause high temperature, insulation breakdown and even explosion and fire of flat cable.

OEM requirements for engine sealing have evolved to include 150,000 mile/10-year durability. These new requirements exceeded the capabilities of existing silicone rubber materials and presented a significant materials development challenge. Dow Corning worked with an automotive OEM and a tier one supplier as partners to address the material performance, processing and design aspects, quickly commercializing a new generation of high-consistency silicone rubber technology called high performance in oil (HPO) materials. HPO compounds exhibit significant improvements in sealability and durability and are currently being used on production automobile engines. In this article, we will discuss our systems approach to engine sealing, as well as the development and use of functional tests that better simulate the actual service environment and sealing performance. Background Silicone rubber gaskets began replacing cork-rubber composites for automotive engine sealing during the 1980s. Since that time, high-consistency silicone rubber (or HCR) compounds have seen widespread use in molded automotive gaskets, primarily in static sealing applications such as cam/valve covers and oil pans. Benefits include long-term flexibility, exceptional temperature stability and resistance to engine compartment fluids. Early HCR silicone compounds for engine gaskets offered sealability improvements and longer service life over previous non-silicone materials. After several years of use, however, it was found that volatile components of these formulations oxidized to amorphous silica in the exhaust stream. Over time, silica deposits can cause fouling of the zirconia elements in exhaust oxygen sensors. To address the problem, Dow Coming first developed a new test method for measuring the low molecular-weight components of the silicone materials, which has since become an OEM standard. A second generation of HCR compounds was subsequently developed, which delivered low volatility and improved compression set properties. Processability was also a key facet of materials development. Traditional physical property requirements were retained, including durometer, tensile strength, elongation, modulus and hot air compression set. Hierarchy system In the past, OEM/supplier relationships have typically been a top-down hierarchy in the design and development of gaskets and sealing materials. The order went from OEM to components supplier to rubber fabricator to the materials supplier. Gaskets were considered a separate entity from the two sealing surfaces and at times were almost an afterthought when' engine components were designed. This frequently resulted in less-than-optimum gasket performance. New systems approach Under the current materials development system, Dow Coming and its OEM/tier one partners have refined their view to consider the gasket as part of die engine sealing system's total design. This represents a shift for most companies, one that more fully integrates the efforts of OEMs and their tiered supply base. The systems approach to engine sealing recognizes that gasket design, material and fabrication all have an effect on performance. The method takes advantage of the unique skills contributed by each sealing team member: OEM;, material supplier,and fabricator/tier one supplier. No individual element of the entire product design and manufacturing process takes precedence over another, resulting in a critical balance of all three areas. This cooperation produces better designs and materials, raising product quality while expediting the commercialization cycle. New material requirements As gasket performance requirements and fabricating goals continued to escalate, it became apparent that the second generation of silicone materials would not meet emerging vehicle performance goals of 150,000 mile/10-year durability. The team had the following design objectives as they worked on a new family of high-consistency silicone compounds: * Provide effective sealing for 150,000 miles. * Maintain the modulus range of the 2nd generation materials for NVH (noise, vibration and harshness) issues. * Optimize compression set in oil vs. air. * Improve compression stress relaxation properties. * Contain cost as indicated by the OEM. * Optimize processing characteristics for gasket fabrication. Throw out the current OEM specification if necessary. In developing the new family of high-consistency silicone compounds, engineers utilized a series of designed experiments to optimize crosslink density, tear strength and hot oil compression set. Because improved compression set resistance directly affects sealing force, it is viewed as an indicator of longer gasket life. Physical property testing Traditional tests for evaluating silicone rubber molding compounds for gasket applications include: * Durometer * Tensile strength * Elongation * Tear strength * Modulus at 100% elongation * Compression set in hot air * Volatility * Heat resistance * Fluid resistance While the existing methods provided important data, materials engineers were convinced that they were not specifically representative of the application. It was determined that functional testing was necessary to more closely simulate the actual service environment under hot oil conditions and speed new product commercialization. Accordingly, new tests were developed and integrated with existing tests to evaluate material candidates more quickly and accurately. Dow Corning, tier one and OEM engineers all contributed to the new-procedures, which were used for both materials screening and validation. Functional testing A brief description of each test: * The hot oil compression set test was designed as a tool for material development and performance testing, because the traditional "hot air" compression set test method (ASTM D-395) was found to be a poor indicator of actual gasket performance. The new procedure is performed as follows: a square, cross-section o-ring (25 mm O.D. x 17 mm I.D. x 4 mm thick) is compression molded 15 minutes at 171[degrees]C. The o-ring is placed into a steel fixture, compressed 20% and submerged in Mobil Super HP 5W-30 SH motor oil at 150[degrees]C. Every two weeks the fixtures are cooled to room temperature, removed from the oil, disassembled and measured for height loss. Compression sets are then calculated from this data. The 6il is changed at every inspection before restarting the test. The cycles continue until 100% compression set is reached. Compared to first- and second-generation materials, the new family of HPO materials show dramatic improvement in compression set resistance (see figure 1). * The accelerated functional test was developed to evaluate the sealability of specific rocker cover assembly designs (including gasket, cover and fastener). In this case, the cover assembly is mounted onto a test fixture and placed in an environmental chamber. Oil lines are then connected and oil heated to 120[degrees]C is circulated through the cover assembly at 2 1/min and 7 kPa. In addition, the fixture and chamber are heated to 150[degrees]C, to simulate hot engine conditions. The test is continued until the sealing system fails, unable to retain the 7 kPa pressure. This functional test provides an opportunity to observe accelerated gasket/cover/fastener performance under conditions closely simulating those in actual service and allows engineers to more accurately predict sealing system reliability. Results of the HPO products' performance in accelerated functional testing shows nearly a fourfold increase in durability over previous commercial materials (see figure 2). * The heat age/pressure test was developed to test the durability of sealing system components with exposure to heat and motor oil. A decay of sealability over time is the eventual result. Test fixtures are prepared by bolting components, with gaskets to be tested, to metal fixture plates. An air pressure test is performed to verify the integrity of the system and the fixtures are then filled with Mobil Super HP 5W-30 SH motor oil and placed in a vented oven. The fixtures are vented to the atmosphere to prevent the buildup of internal pressure. The oven is heated to 150[degrees]C and the test fixtures are heated for three- or four-day intervals. At the end of the specified period, the fixtures are cooled and removed from the oven, the oil is drained and an air pressure test is performed. The pressure required to cause a leak (if less than the maximum test pressure of 35 kPa) is recorded. Fresh oil is added and the test cycle repeated until the sealing system is unable to maintain 7 kPa. The test shows that the third-generation HPO materials outperform previous commercial materials (see figure 3). * The compression stress relaxation (CSR) test is conducted using 19 mm O.D. x 12.5 mm I.D. x 2 mm thick o-rings die-cut from slabs according to ASTM procedures. The rings are placed in Shawbury-Wallace test jigs, compressed 25% and then immersed in IRM-903 oil. A hot air circulating oven is used to heat the fixtures and oil to 150[degrees]C. Sealing force measurements are taken after one and three days, then weekly throughout the balance of the six-week test period (1,008 hours), after which the percentage of sealing force retention is determined. The new HPO materials exhibit significantly improved CSR retention over the previous production material (see figure 4). * As part of the design/material/processing triangle, the fabricator performed molding tests of the new HPO materials using the most severe mold available. These tests allowed the new materials to be examined for demolding, deflashing and scrap rates compared to existing production materials. Several material variations were evaluated to find the optimum balance of physical properties and processing characteristics. Key mold parameters were identified to make the materials less process-sensitive and the new formulations have demonstrated equal or improved processing when compared to 1st- and 2nd-generation products. * During die dyno test phase, the HPO materials were evaluated by the OEM on 300 hour, 500 hour and other engine durability cycles. They were found to provide the necessary longevity to survive all dyno tests and subsequently received OEM approval. * The HPO materials were also subjected to extensive fleet testing, using taxi, limousine and police department fleets as the test bed. These were chosen intentionally to expose the test vehicles to high mileage accumulation and extreme temperatures. The fleet evaluations have demonstrated that the HPO materials deliver increased service life over previous materials and as a result a major U.S. OEM began using the new compounds in production in Q2, 1995. Summary The new, 3rd-generation HPO materials are currently being used in rocker cover and cam cover applications. They are also being evaluated for timing chain cover gaskets and oil pan gaskets. These materials improve long-term durability of engine sealing systems without a sacrifice in processing characteristics. Along with its-partners, Dow Coming has adopted a systems approach to engine sealing, as it continues rapid development and commercialization of new silicone materials. The cooperation between OEM, materials supplier and fabricator/tier one supplier capitalizes on the strengths of all the parties involved in engine sealing to optimize design, processing and performance characteristics. Future material goals include continuous improvement of compression set values, compression stress relaxation properties and functional performance in hot oils. [Figures 1-4 ILLUSTRATION OMITTED] by Lawrence D. Fiedler, Thomas J. Hebda, Edward M. Kucinski, Mark H. Lee, Dow Coming Corp. and Jeffery K Zawadzke, Dow Coming STI

The excellent properties of silicone rubber, such as flexibility, chemical resistance and stability at high temperatures, often cannot be exploited optimally because of the hydrophobic surface properties.
Painting and gluing is almost impossible because of the low surface energy and the sticky and static surface.

Nanon has developed two technologies, Softplasma and Cohancement, that create further possibilities using silicone rubber. Softplasma is a surface-treatment process that polymerizes a nano-scale layer with hydrophilic functional groups on the silicone rubber surface. The permanent layer bonds strongly to many types of glue or paint. In Cohancement, undesired residues from the silicone rubber are removed in an environment-friendly process. This process is a substitution for the conventional heat tempering process used to post-cure silicone rubber.

This article will describe different applications of these technologies.

Softplasma What is plasma?

Plasma is an ionized gas. While, e.g., the sun or stars are totally ionized, artificial plasmas used for surface treatment contain only about 0.1-10 ppm ions and electrons. The rest are neutral species.

Artificial plasma can be realized by exposing a gas to an energy field at low pressure.

Etching When initiating a plasma, electrons are accelerated in the electrical field. When hitting an atom or molecule of the gas, ionization or fragmentation can occur. Positively charged ions from the gas phase hit the substrate surface and crack chemical bonds of the outer layer. This leads to etching of the surface because atoms and small fragments evaporate. The etching cleans the surface and creates active sites where the plasma-polymerized layer can be bonded later on.

Plasma polymerization A monomer is applied to the plasma, activated and polymerized on the substrate surface. The power input of the plasma has a direct influence on the character of the plasma reaction. At high energies, the monomer that is led into the plasma is completely fragmentized and radical formation occurs in the gas phase, leading to a highly crosslinked polymer. At low energies, the lnonomer structure is preserved and radical polymerization occurs on the substrate surface.

Influence of different energy levels on the plasma polymerization Ethyl-2-cyanoacrylate was used as monomer. It was evaporated and fed into the plasma chamber, where it was activated in argon-plasma at different energy levels. As substrate, NaCl-crystals were used. After the process, the crystals were analyzed in a Thermo FTIR spectrometer by transmission measurements (figure 1).

[FIGURE 1 OMITTED] The typical peaks at 1,745 [cm.sup.- and 1,249 [cm.sup.- are decreasing when the power level is raised. That means that the ester group cannot withstand high energy levels without degrading Softplasma Softplasrna is the trade name for a low pressure plasma treatment and polymerization technology developed by NKT Research. Softplasma allows plasma polymerization at very low energies without serious damage to either the substrate or functional groups of the monomer. To obtain this low energy plasma, a three-phase AC plasma with 50 Hz is used. The shape of the electrodes gives the opportunity to create homogenous, 3D-plasma that oilers the possibility to treat items with various geometries.

In theory, all kinds of monomers could be used for plasma polymerizing to obtain desired surface properties. However, the monomer has to fulfill the condition of being evaporable in vacuum at room temperature.

It depends on the application which kind of functional group is required on the surface to create better bonding to a top coating. Vinyl or acrylic compounds with suitable functional groups are often used as monomers in order to obtain the requested surface properties.

Applications Coating of silicone rubber with PU Coating of silicone robber switches with polyurethane coating becomes possible when a plasma pretreatment is made (figure 2). The plasma treatment creates NH--and CN--groups on the surface that give a higher surface energy and a good bonding to the PU top-coating.

[FIGURE 2 OMITTED] Over-molding of polyamide with silicone rubber When over-molding polyamide with silicone rubber, it is difficult to obtain good adhesion between the materials without using primer chemistry and special silicone rubber (figure 3).

[FIGURE 3 OMITTED] With Softplasma, we apply a silicone-like surface with a low surface energy onto the polyamide that afterwards is able to create adhesion to the over-molded silicone robber (figure 3).

Cold tempering (Cohancement) Problems from plasma When starting plasma treatment of silicone, we soon had to cope with problems concerning the volatiles that evaporate from silicone rubber. These silicone oligomers migrate to the material's surface during vacuum treatment, and the plasma polymerization is made on an oily film instead of the silicone surface. A further coating is not possible. When looking for solutions to remove the volatiles, we investigated different kinds of methods and found that carbon dioxide (C[O.sub.) under pressure is a good solvent for silicone oligomers.

When C[O.sub. is pressurized, it becomes liquid or supercritical (figure 4). In these states the surface tension is 0-5 mN/m.

[FIGURE 4 OMITTED] Because of its low surface tension, C[O.sub. wets most materials completely, and especially silicone rubber. The liquid goes through the silicone rubber, swells it and dissolves silicone oligomers and by-products from catalysts and peroxides. Additionally, other compounds can be impregnated into the silicone material, leading to new properties.

Cold tempering Today, the majority of silicone rubber is post cured in heat for several hours to get rid of by-products from the vulcanizing step and to remove low molecular silicone compounds from the rubber. The process often takes a long time, and sometimes silica-dust from decomposed silicone is formed on the silicone robber surface, which causes troubles in subsequent surface treatments. Another problem is the healing (re-polymerization) of cuts and holes caused by heat from the post-curing step that makes it difficult to make the final design of the silicone rubber item in the mold already. To remove these drawbacks, a good alternative is to use supercritical or liquid C[O.sub. to post-cure silicone rubber. We developed the cold tempering process that uses liquid C[O.sub. (at 40 bars, 10[degrees]C), which makes the process much cheaper and easier to handle than a process under supercritical conditions (at least 31 [degrees]C, 74 bars).

The following analyses were made: Baby soothers made of silicone rubber (LSR) were post-cured by common heat tempering (4 hours, 200[degrees]C, air ventilated) and by cold tempering (washed in liquid C[O.sub., 40 bars, 10[degrees]C, 1 hour). Afterwards, the remaining content of volatiles was analyzed by EN 14350-2 and by Nanon's acetone soxhlet method. Mechanical properties were measured by customers' standards. GC and GPS analyses of the residues were made by the customers' standards. Cut healing was visually investigated.

The effect of removal of volatiles and low molecular silicone oligomers is shown in table 1.

In comparison to the EN 14350-2, the acetone soxhlet method can be used to determine other residues besides volatiles. In acetone, low molecular residues, which would not evaporate at atmospheric pressure at 200[degrees]C, are dissolved, leading to a higher value of weight loss.

Gas chromatography analysis showed that harmful cyclic siloxanes in the range of D4 to D20 are removed. But also in the range up to D30 (20 cST), GPC analysis shows significant decrease of tree silicone oligomers.

The mechanical properties are shown in table 2.

The C[O.sub. treatment has no negative impact on the robber-like properties of the silicone. Especially the values of modula 100% and 300% show that there is no further cure reaction in the C[O.sub.

process. However, there is a difference in comparison to the heat cure values of the compression set, tear resistance and hardness. These values do not change in the C[O.sub. treatment but normally change in heat curing.

Prevention of cut-healing The cuts did not heal during the C[O.sub. process and we could state that the cut edges were less sticky than before the treatment. The final dimensions and details of the silicone rubber being unaltered during the treatment with liquid C[O.sub. means that no re-polymerization takes place.

Sterilizing effect in cold tempering From literature, it is known that supercritical C[O.sub. is an unfriendly environment for bacteria.

Initial trials have been started to determine if the liquid C[O.sub. process can give the same effect. E. coli bacteria have been applied to a silicone rubber surface and the samples have been treated in liquid C[O.sub. for two hours. Afterwards, the numbers of bacteria have been analyzed by measurement of the pH value. The pictures (figure 5) show that there are no bacteria on the C[O.sub. treated sample.

Because of the conditions in liquid C[O.sub. (10[degrees]C, 40 bars), one can state that the bacteria were not killed by extreme temperature, but by an effect of the pressure or the C[O.sub..

[FIGURE 5 OMITTED] This article is based on a paper presented at Silicone Elastomers 2006, a Rapra Technology conference. (www.rapra.net/ conferences).

by Maike Benter, Anne-Marie Jensen and Thomas Emil Andersen, Nanon A/S, Denmark (www.nanon.dk)