Extruded FEP Insulated Wires

FEP is the softest of the fluorocarbon co-polymers offered by Exotherm Cable and is, beside an excellent insulation material, likely to be the most favorable fluoropolymer for cable jackets.
FEP has excellent non-ageing characteristics and a broad useful temperature range from about -200ºC to +200ºC continuously. Used as insulation FEP passes several severe flame tests as for instance the IEEE 383 and has also the UL 94 V-0 rating. The chemical inertness of the material is excellent and is one of the most chemical resistant polymers.

Extruded FEP insulated high voltage wire and cable offers exceptional dielectric strength without the disadvantages common to equally rated silicone rubber insulated cables. As a result, cable assemblies or cable bundles are of smaller diameter and therefore take up substantially less volume and have a smaller bend radius which allows the designer to better utilize the space within the system. It has good corona inception qualities and its construction gives it excellent durability and resistance to dielectric/cooling fluid degradation.

Additionally, FEP insulation, being a harder material than silicone rubber, is not prone to pin-holing and high voltage punch-thru when the cable surface is abraded or when strands break during in-field service. FEP is also more resistant to damage when making contact with sharp edges. FEP cable should not only be considered for use in cable assemblies, but as high voltage hook-up wire within encapsulated high voltage power supplies, TWTs and transformers.

Low DC corona inception, particularly after numerous temperature cycles, is another advantage of FEP over silicone cables. PTFE tape wrapped cable, which is similar to FEP in dielectric strength and corona inception, is difficult to bond to because of its multiple spiral cross section, irregular surface and variations in diameter.

The material is excellent for use as a dielectric – it has got an excellent dielectric constant of 2.1, a high dielectric strength, excellent resistivity and an excellent dissipation factor of magnitude 0.0005. Its low dielectric constant is essentially constant with changing frequency or temperature.

Exotherm Instruments’s FEP wire meets the requirements of MIL-W-16878/11, 12 & 13

Properties of FEP Fluorocarbon Resin
Physical, Thermal and Electrical Properties Typical Values
Specific Gravity 2.14
Tensile Strength (PSI) 3,500
Elongation (%) 325
Flexual Modules (PSI) 90,000
Thermal Conductivity (cal/sec/cm°F) 6X10
Continuous Use Temperature (°C) 204
Melt Temperature (°C) 255–265
Low Temperature Limit (°C) -240
Hardness Durometer D56
Water Absorption (%) <01
Flame Resistance Excellent
Dielectric Constant, 60-10 Hz 2.1
Dissipation Factor, 60-10 Hz <.0007
Volume Resistivity (Ohms-Cm) <10
Surface Resistivity (Ohms/Sq.) <10
Resistance to: Rating
Cold Flow or Cut Through Fair
Ultraviolet Radiation Excellent
Electro-Mechanical Stress Cracking Excellent
Chemical-Mechanical Stress Cracking Excellent

Advantages of Extruded FEP wire over Wrapped PTFE Wire
Exotherm Instruments produces these FEP wires using Conventional Hot Melt Extrusion process, which has several advantages over Wrapped PTFE wires as listed below.
  • Uniform Diameter
  • Smooth Outer Surface
  • Strong bonding between Insulation and core conductor
  • Easy stripping by Automatic stripping M/c or hand held stripper
  • Can be produced in Continuous long length.

  • Hook up Wire for Control Panels
  • Wire Harness Assembly
  • Motor & Transformer Lead wires
  • Batteries, UPS & Invertors
  • Plenum Cables
  • Halogen Lamp Holders & Lanterns
  • Electric Cooker, Micro-wave Oven, Electric Thermos, Air-Conditioning Equipment
  • Computers, Laptops, PDA’s
  • Medical and scientific instruments
  • Aircraft Wiring, Defense & Signal Equipments.
  • Process Instrumentation
  • RTD, Thermocouples and Thermistors
  • Sensors & Igniters
  • Semiconductor & Electronics

Contact Us

Phone :+91 22 2889 1611
Fax : +91 22 2889 1612
E-mail: sales@exotherminstruments.com