high temperature cable Teflon cable FEP/PFA/PTFE/PVDF/ETFE

A serendipitous discovery that changed the course of human society.

I. History of Teflon(FEP/PFA/PTFE/PVDF/ETFE)

1、Narrow sense of Teflon
In the early days, Teflon referred solely to polytetrafluoroethylene, which was accidentally discovered in 1938 by chemist Dr. Roy J. Plunkett in a DuPont laboratory in New Jersey, USA. While he was trying to make a new chlorofluorocarbon refrigerant, polytetrafluoroethylene polymerized in a high-pressure storage container (the iron in the container’s lining acted as a catalyst for the polymerization reaction). DuPont patented it in 1941 and trademarked it in 1944 under the name “Teflon”.

Teflon is a revolutionary material with a history full of innovation and technological breakthroughs. Scientists have described the invention of PTFE as “an accident of chance, an eureka moment, a stroke of luck – or even a mixture of all three”. Whatever the case, one thing is certain: PTFE has revolutionized the plastics industry and spawned endless applications for the benefit of mankind.

1938: Roy J. Plunkett, a chemist at DuPont, accidentally discovers PTFE while researching refrigerants.
World War II: PTFE was used for military purposes because of its excellent chemical inertness and electrical insulation properties, such as as an insulating material in the Manhattan Project for the atomic bomb.
Commercialization: In 1945, DuPont began commercializing PTFE and named it Teflon (Teflon). Initial applications were focused on industrial applications such as lining of chemical equipment and anti-corrosion coatings.
1950s: As technology advanced, PTFE began to be used in more applications, such as cookware coatings, because of its non-stick properties and ease of cleaning.
1960s: PTFE was introduced into textiles for waterproof and breathable fabrics such as Gore-Tex.
1970s: PTFE is used in medical applications such as vascular grafts and surgical sutures.
1980s to present: PTFE is used in a wide range of applications, including automotive, aerospace, construction, electronics and many other industries.

2、Generalized Teflon cable

Subsequently, DuPont developed a series of products in addition to Teflon cable PTFE resins, so that Teflon now refers to a family of fluoroplastics, including including PTFE (polytetrafluoroethylene), ETFE (ethylene tetrafluoroethylene copolymer), FEP (fluorinated ethylene propylene copolymer), PFA (perfluoroalkylates), and PVDF (polyvinylidene fluoride), among others.

These Teflon materials are widely used in a variety of industries due to their excellent resistance to high temperatures, chemicals and electrical insulation. It has a series of unique properties and advantages, these characteristics make it in many ways beyond other plastic materials, so Teflon also has the reputation of “king of plastics”, with excellent high temperature resistance (temperature resistance: -200 ℃ ~ +260 ° C). Teflon is widely used in many industrial fields, such as chemical industry, rail transportation, energy, aviation, automotive and medical equipment.

II.High temperature Teflon cable industry applications

Due to the excellent performance of Teflon cables, they are widely used in the following industries:

Aerospace: for ultra-high temperature conductors in airplanes and spacecraft.
Petroleum industry: as winding wire and connecting wire for submersible oil pump motors, maintaining performance at extreme temperatures.
Atomic power plants: for winding coils in nuclear island drive mechanisms, capable of long-term use under irradiated conditions.
Naval industry: seawater resistance and lightweight design make it widely used in ships.
High-speed traction locomotives: suitable for high-speed trains and other transportation equipment.
Automotive manufacturing: for automotive electronic systems.
Natural gas: Used in antenna sleeves, valve seats, electrical connectors, etc., capable of handling extreme temperatures and high-pressure environments.
Semiconductor and electronics: Teflon is used as an electrical insulator and mechanical component for semiconductor production and electronic equipment.
Food processing: Teflon’s non-adhesive and easy-to-clean properties make it suitable for food contact applications.
Medical equipment: Used in MRI machines, X-ray equipment and other cables that require high purity and low signal interference.
Military and defense: for communications and control systems in harsh environments.

III.High temperature Teflon cable structure

Conductor: Copper or silver-plated copper conductor for efficient transmission of power or signals.
Insulation: One or more of the Teflon materials mentioned above to provide electrical insulation and protection.
Sheathing: Some cables may also include an additional layer of Teflon sheathing or other materials for enhanced mechanical protection and environmental protection.
Shield: Where EMI reduction is required, cables may include a braided metal or foil shield.

[Technical Parameters]

Operating temperature: -200°C to +260°C
Insulation material: Teflon (PTFE cable)
Conductor material: bare copper or silver plated copper-nickel
Insulation thickness: according to cable specifications and standards
Flame retardant rating: UL1581 compliant

IV.The special performance and advantages of high temperature Teflon cable

Special Properties

High and low temperature resistance: Teflon material has a wide range of temperature resistance, from low temperature -200°C to high temperature over 260°C, and even at extreme temperatures it still maintains good physical and electrical properties.
Chemical resistance: Teflon material has excellent resistance to most chemicals, including acids, alkalis, solvents, etc., which enables the cable to be used safely in harsh environments such as the chemical industry.
Low coefficient of friction: Teflon has an extremely low coefficient of friction, which means that dirt and corrosive substances are not easily attached to the surface of the cable, making it easy to clean and maintain.
High dielectric strength: Teflon cables have a high dielectric strength and can withstand high voltage without breakdown, making them suitable for high voltage power transmission and signal transmission.
Non-adhesive: Teflon’s non-adhesive characteristics reduce the likelihood of contaminants accumulating in the cable during use, especially in applications in the food processing and pharmaceutical industries.
UV and Radiation Resistant: Teflon materials have excellent UV and radiation resistance, making them suitable for cable applications in outdoor and high radiation environments.

V. High temperature Teflon cable material properties and temperature resistance range

Teflon’s high temperature resistance range varies with different types, thicknesses and processing methods. In general, Teflon can withstand the following temperatures.

1. Short-term temperature resistance: 260°C (430°F) or so.

2. Long-term temperature resistance: In practice, Teflon can usually withstand temperatures up to 260 ° C (430 ° F), but long periods of time at this temperature may lead to material deterioration and performance degradation.

Polytetrafluoroethylene (PTFE cable): PTFE is a highly stable fluoropolymer with a short-term temperature resistance of up to 260°C and a long-term service temperature range of -196°C to 260°C (430°F).

Tetrafluoroethylene-Perfluoroalkoxy Vinyl Ether Copolymer (PFA cable): PFA is similar to PTFE but has a lower melt viscosity, making it easier to process into complex shapes.PFA has a similar operating temperature range to PTFE but has better mechanical strength at higher temperatures.

Fluorinated ethylene propylene copolymer (FEP cable):FEP also has good high temperature and chemical resistance, with an operating temperature range of about -200°C to 200°C. It is also a good choice for the most demanding applications.

Cross-linked polytetrafluoroethylene (XLETFE cable): The mechanical strength and heat resistance of PTFE is enhanced by chemical cross-linking, and its temperature resistance range is similar to that of PTFE.

Ethylene-Tetrafluoroethylene Copolymer (ETFE cable):ETFE has high abrasion and tear resistance and has an operating temperature range of approximately -70°C to 150°C, although some special grades of ETFE can withstand higher temperatures.

Ethylene Chlorotrifluoroethylene Copolymer (ECTFE ECTFE has good chemical resistance and mechanical strength, and has an operating temperature range of approximately -65°C to 150°C.

Polyvinylidene Fluoride (PVDF cable: PVDF has excellent weathering and chemical resistance, with an operating temperature range of approximately -46°C to 150°C.

Table of Properties of Various Fluoroplastics

Fluoroplastic Properties
Performances	ASTM or Unit	PTFE	FEP	PFA	ETFE	ECTFE	PVDF	PCTFE
			Mechanical property
Relative density	D792	2.18	2.15	2.15	1.74	1.68	1.77	2.13
Elongation at break/%	D638	200~~450	250~330	280~400	420~~460	200~300	300~450	150
Tensile strength/MPa	D638	14~48	19~35	28~31	42~~47	41~~54	31~43	36.5
Bending strength/MPa	D790	Unceasing	Unceasing	Unceasing	38	48	59~66	59
Compressive strength/MPa	D695	24	15	17	8. 8~~12	8.8~12	80	38
Modulus of elasticity of tension (Young's)/MPa	D638	393	345	500~~600	586~655	1655	1103	1427
Bending modulus/MPa	D750	490~~586	538~~634	648~-682	883~~1179	1655	621~1158	1241
Hardness (Shore D)	D636	D50~~65	D5S	D55~60	D7S	D75~90	D75~85	D90
Coefficient of friction	relative example	0.02	0.05	0.2	0.06	0.19	0.4	—
Abrasion resistance 1000 times	Taber	12	14~~20	9~17		0.005	5~15
Lzod Notched impact strength (23°C)/(kJ/amP)	D256	6.3	Unceasing	Unceasing	Unceasing	Unceasing	8.4	10.5
Thermal performance
Melting point/℃		327	260	305	267	240	171	212
Maximum continuous operating temperature（20000h）/℃		260	200	260	150	150~170	129	132
Flame retardant（UL94）		V-o	V-o	V-o	V-o	V-O	V-o	V-0
Coefficient of linear expansion（D696）/（×10-3℃-1）		>11.6	8.3-~10.5	13	13	Unceasing	4.2	7.0
Embrittlement temperature/℃		-268	-268	268	100	-76	-62	240
			Electrical property
Dielectric constant	(D150,101Ha)	2.1	2.1	2.1	2.6	2.5	7.72
Dielectric constant	(DI50.10*Hz)	2.1	2.1	2.1	2.6	2.59	6.43
Dielectric strength (0.254unm static film)/(kV/mm)	(D149)	>1400	>2000	>2000	1600	—	>1080
Bulk resistivity	(T257)	>101*	>101	>1018	>104	>104	2×1014	101*
Surface resistivity	(D257)	>10U	>101T	>10Ir	>104	10i4~10it	5×10i4	101s
			General Characteristics
Resistant to chemical solvents	D543	awesome	awesome	awesome	awesome	awesome	very good	good
Water absorption (24h)/%	D570	<0.01	<0.01	<0.03	<0.03	<0.1	<0.04	<0.01
Index of refraction		1.35	1.338	1.34	1. 40	1. 447	1.42
Oxygen limiting index (OLI)	D2863	>95	>95	>95	31	60	43	100

It should be noted that the above data is for reference only. The temperature resistance range in actual applications may be affected by factors such as material quality, thickness, processing methods and environmental conditions. When selecting Teflon materials, please be sure to refer to the product specification or e-mail TST CABLES engineers for accurate temperature resistance information.

VI.High temperature Teflon cable standards and testing

UL1581 standard: Teflon cables need to meet the requirements of UL1581 standard, including electrical performance, combustion performance, physical properties and other aspects of the test.
Electrical performance test: including conductor resistance test, voltage resistance test, insulation resistance test, etc.
Combustion performance test: including vertical combustion test, horizontal combustion test, etc., to ensure that the cable has good flame retardant properties.
Physical performance test: including tensile test before and after aging, tensile test, etc. to evaluate the mechanical strength and durability of the cable.
Environmental adaptability test: including high and low temperature resistance test, chemical corrosion resistance test, etc., to ensure the performance and safety of cables in different environmental conditions.

Customized Teflon High Temperature Cable with Custom Cable Manufacturer TST CABLES

TST CABLES Teflon cables push the limits of high temperatures in modern industry. Excellent temperature resistance from -200°C to 260°C, corrosion resistance, no fear of chemical attack. Flexible and abrasion-resistant, stable transmission, escorting your equipment. Aerospace military quality, so that every meter of cable becomes a model of safety and efficiency. If you have demand for Teflon cable or want to get free samples, you are welcome to contact us (lixiangchao@testeck.com) by email or phone at any time, looking forward to win-win cooperation with you!

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