The Effects of Chemical Foaming Perfluoropolymers
on Rheology Enabling Pressure Extrusion
David Braun, Kevin Slusarz, Charles Glew, Richard Speer*, Gary Paddison*
Cable Components Group, LLC
Pawcatuck, CT
860-599-5877 – dbraun@cablecomponents.com
Abstract:
Perfluoropolymers such as Fluorinated Ethylene
Propylene (FEP), Perfluoroalkoxy (PFA), and related
copolymers such as Tetrafluoroethylene
Perfluoromethylvinylether Copolymer (MFA) are ideal
insulating materials for fire rated high-speed data cables. They
offer an outstanding balance of properties including low
dielectric constant and dissipation factor along with high flame
retardancy, low smoke, and high operating temperatures. These
Perfluoropolymers are used for insulating copper wire and the
traditional insulation process is tube extrusion. Inherently, tube
extrusion is susceptible to cone breaks of the aforementioned
materials that limit its processing speeds, especially when thin
wall foams are extruded in this manner. This paper
characterizes chemical foaming as a method to extrude FEP or
MFA using pressure extrusion for thin wall insulation or twisted
pair local area network cables.
The impacts of extrusion process inputs including: Melt Flow
Index, Extrusion Shear Rate, Process Temperature, and Foam
Rate on the characteristics of Chemically Foamed
Perfluoropolymer products are identified. The paper that
follows will show that the chemical foaming process changes
the rheology of FEP, increasing the effective melt flow rate
while dramatically lowering extrusion pressures so as to enable
higher running speeds while utilizing pressure extrusion for
foamed insulation. Optimized process conditions are identified.
Introduction:
The development work that has been done is both
evolutionary and revolutionary for the insulation of local area
network cables. From a market perspective, the sales LAN
cables in 2009 which was arguably an off year for LAN cable
sales, was 4.0 Billion feet of 4-pair Plenum rated Category cable
in North America. The overwhelming predominant materials
used were solid FEP and MFA for the insulation of these
plenum cables. This equates to approximately 16 million
pounds of solid insulation for Unshielded Twisted Pairs (UTP)
Category 5e, 6, 6e and 6A.
Traditionally, due to their high viscosities, extrusion tubing of
FEP and MFA has been the only method available to cable
manufacturers for insulating wires requiring a CMP rating. The
relatively high melt strengths of these perfluoropolymers have
been more than sufficient to allow high-speed reliable insulation
of solid layers. Today’s rapidly evolving market continues to
challenge manufacturers to produce higher speed cables with
smaller diameters. An increasingly important tool for achieving
those objectives is the foaming of perfluoropolymers used to
insulate conductors due to reduced material content and
International Wire & Cable Symposium
improved electrical properties. Unfortunately, experience has
shown that perfluoropolymer foams do not draw as readily as
solid extrusions, limiting their draw-down ratios and production
speeds. From a technical perspective, chemically foaming thin
wall Category cable insulation is an enabling technology to
enhance electrical performance while foaming insulations at
faster speeds while lowering the combustible footprint within
the plenum areas of commercial buildings. Therefore, the focus
of this paper is on insulating copper wire through the use of
pressure extrusion while foaming it at 35% to 45%.
Background
The focus of the test methods were to assess and
compare the processing of solid FEP versus chemically foamed
FEP. A traditionally used UTP solid insulation FEP grade was
used for comparison and noted as our FEP solid control. It had
the following properties - melt index 26 g/10 min; specific
gravity 2.15; U.L. recognized for plenum insulation; LOI >95.
The chemically foamable comparison grade used the
aforementioned solid FEP as a base resin and compounded with
both chemical foaming agents and nucleating agents. The
formulations were based upon the patent pending chemically
foamable Perfluoropolymer technology known as
“FluoroFoam®”. Much work has been performed to show the
effect of foam on the rheological and processing properties of
thermoplastics. It has been demonstrated that the generation of
foam acts like a plasticizer and can allow processing of
materials at conditions where a non-foamed plastic would not
operate due to elevating the critical shear rate of the solid
material.
This paper will investigate this phenomenon as it relates to FEP
perfluoropolymers. Experimental data will be presented
showing how a chemically foamed fluoropolymer can extend
the processing range before the onset of melt fracture allowing
the material to be used in new applications such as pressure
extrusion on small diameter wire. Figure 1 shows a cross-
section of the pressure extrusion setup where polymer coats the
wire inside the die and the final diameter is determined by the
die tooling. Figure 2 depicts a more traditional tubing extrusion
arrangement where the polymer is drawn onto the wire outside
the die.
The work presented in this paper has been performed to identify
whether the lower apparent viscosity generated from chemically
foamed perfluoropolymers could be exploited to allow pressure
extrusion. The benefits of pressure extrusion include higher line
speed, reduced spark failures (insulation voids) and the
elimination of cone breaks inherent in extrusion tubing.
143 Proceedings of the 59th IWCS/IICIT
 F
Figure 3: Labo
oratory Shear Rate vs. Visco
osity

xtrusion Trials
2.3 Ex s
Extrusioon trials were perrformed on a prodduction wire coatting line. The
line connsisted of a poweer payoff for the wire, a Roots-Teech induction
Figu
ure 1: Pressurre Extrusion Setup
S
preheateer, a 38mm (1.5 inn) 24:1 L/D Entwwistle Extruder, a standard
s FEP
meterinng screw with no mixing
m section, Unitek
U USCC-F 3//20 crosshead
with a 1.016
1 mm (0.0400 in) diameter pressure die, 12m (440 ft) cooling
trough, belt capstan, andd a take-up. Thiss line is also equuipped with a
Sikora XY
X laser gauge anda a capacitance gauge. Solid coppper wire with
a diameeter of 0.605 mm m (0.0238 in) was coated with the Control FEP
and thee chemically foam mable FEP at an insulation thicknness of 0.203
mm (0.008 in). Each maaterial was run at three
t different exttruder speeds
in a preessure extrusion setup.
s At each coondition the proccess variables
were reecorded and wiree samples were collected
c for surfface analysis.
Some ofo the solid FEP experiments
e were not able to be peerformed due
to exceessive back presssure on the extruuder. In additionn, trials were
conductted on the chemiically foamable formulation
f in a tubing
t setup.
Optical microscopy of a cross-section of the insulatioon showed a
uniform
m cell structure forf both tubing and pressure exxtrusion. The
averagee cell size was appproximately 0.0255 mm (0.001 in) inn diameter.

esults
3. Re
The exttrusion performannce was evaluateed at 10 screw RPMR for both
Fig
gure 2: Tubing
g Extrusion Se
etup materiaals at a 30% foaam rate. Figure 4 shows the linne speed for
Chemiccal Foam (denotedd as B) versus thee Control. As can be seen from
the grapph the line speedd was higher for the foamed sampple. Figure 3
shows the
t back pressure for Chemical Foaam (B) versus the control. This
2 Experimeental
2. also shoows that the addittion of the foaminng package causees lower back
2 Materials
2.1 pressuree on the system.
The control sampple and the chem
T mically foamable sample used thhe
s
same base FEP material.
m A suitaable chemical fooam formula wiith
n
nucleant, foaminng package, and
d lubricant was compounded innto
thhe control FEP.

2 Rheologic
2.2 cal Testing
Capillary rheology was measureed on the sampples on a Dyniscco
C
L
LCR7000 consttant shear-rate rheometer att three differeent
teemperatures. A 1.016 mm (0.04 40 in) diameter capillary die wiith
a 15:1 L/D annd a 45° entrance angle wass used. Viscosiity
m
measurements w
were made at sheear rates of 1000, 400, 800, 10000,
1
1500, 3000, 45000, 6000 reciprrocal seconds at 340°C (644°F F),
3
360°C (680°F), and 380°C (716 6°F). Figure 3 shows
s the contrrol
a the chemicaally foamable formula
and fo (denotedd as Formula B).B
T figure show
The ws that the viscossities are similarr across the rangge
o shear rates andd one would exp
of pect them to show w similar pressuure Figure 4: Line Spe
eed vs. Formu
ulation, 10 Scrrew RPM,
d
drops during processing. 30% Foam Rate
R

 
International Wire & Cable Symposium 144 Proceedings of the 59th IWCS/IICIT
 psi whiile compared to the FEP chemiccal foam at 35% foam which
was under
u 2,000 pssi at similar speed.
s This deemonstrative
differennce in psi enablees pressure extruusion of chemically foamed
FEP a high
h line speedss and teaches whhat we will laterr describe as
the plassticization effectt.

Furtherring the study and

a trials with a pressure extruusion set-up,
Figure 6 denotes trials with solid FEP (control) versuss chemically
foamedd FEP (B) whereein the extrusionn pressures and screw
s speed
are meeasured. The ressults denote the onset of melt fracture
f at 7
w unsustainable pressures of 6,000
RPM with 6 psi encounntered above
15 RPMM. On the other hand, chemically foamed FEP was smooth
and waas extrudable in the same pressuure set-up throuugh 25 RPM
with prressures lower thhan 4,500 psi. Based
B on this daata, the trials
were reefocused on optiimizing pressuree die designs so that
t running
speeds could reach the meaningful millestone of 300 mpmm (~1,000
F
Figure 5: Pres
ssure vs. Form
mulation, 10 Sc
crew RPM, 30%
% fpm) foor thin walled chemically foam med FEP. Furtherr trials were
Foam
m Rate conduccted and resulteed in an insulatted conductor of o 0.91 mm
(0.036””) diameter and wall thickness of
o 0.15 mm (0.0006”) with a
The previously described rheo
T ology data shoowed the foameed foaminng level of 35%.
s
sample had simillar viscosity verrsus shear rate as compared to thhe
C
Control. Equation #1 shows the relationship between
b flow ratte, The prressure set-up ran without sppark failures orr insulation
p
pressure drop, annd viscosity for flow
f through an annulus [1]. breaks.. By contrast, thhe same wall thicckness at 300 mpm
m (~1,000
fpm) and
a 35% foam rate was attem mpted with tubee extrusion.
Repeattedly spark failuures occurred ata the required 1,500 volts
∆ (1)
1 w cone instabiility and occasioonal cone breaks.
along with

The data shows a lower pressure drop (ΔP) and higher

T h output rattes
(Q) for the foam med sample. Based on the data that t was collecteed
Onset of Meelt Fracture
thhe apparent visccosity (μ) of the foamed material is approximateely
3 times lower thaan the Control FEP although the capillary data did d
n show this diffference. It has been stated in liiterature that meelt
not
fr
fracture occurs once
o a critical shear
s stress at the
t wall has beeen
e
exceeded. In ordder to prevent meelt facture some of the processinng
p
parameters that can influence th he onset of mellt fracture includde
inncreased temperature at the diie land, lower extrusion speedds,
loower molecular weight, lower viscosity,
v increassed cross-sectionnal
a of the die [22]. Based on this the lower apparrent viscosity wiith
area
thhe foamed material should lead to higher outputt rates before meelt
fr
fracture becomess an issue.
ure vs. Screw Speed for Pre
gure 6: Pressu
Fig essure
A critical factoor allowing preessure extrusioon is a compleex
Exttrusion, Chem
mical Foam Forrmulation, Op
ptimized
p
phenomenon knoown as the redu uced apparent viscosity
v of foaam
Tooling
e
extrusions. This phenomenon haas been identifieed in the literatuure
a arising from thhe plasticizing effect of cell form
as mation and growwth
[3]. It causes a dramatic
d reductiion in viscosity which can, undder
Table 1: Process Conditions fo
or Chemically Foamed
thhe right circum mstances, increaase the critical shear rate of a
FEP Press
sure Extrusionn at 1,000 fpm
m
p
polymer. We thheorize that wheere cells form in the process is
c
critical because apparent
a viscositty reduction is greatest
g during thhe Zone #1 310°C (590°F)
g
growth stages off cell formation. Thus a foam thhat has begun ceell Zone #2 385°C (725°F)
innitiation prior too the forming diee will be the mosst apt to producee a Zone #3 393°C (740°F)
s
smooth pressuree extrusion surfaace. The chemical foam used in Zone #4 404°C (760°F)
thhis study beginss cell growth jusst past the extrusion breaker plaate Clam
mp 388°C (730°F)
a continue to grow
and g as it passess through the forrming die. Flangge 388°C (730°F)
Head 388°C (730°F)
Figure 4 shows the line speed under
F u a pressuree extrusion set-uup Die 388°C (730°F)
c
comparing solid FEP (control) versus chemicallly foamable FE EP
(B). Noteworthy, under similar temperatures,
t prressure die desiggn Screw
w Speed 24 RPM
R
toooling to processs a 0.15 mm (00.006”) wall thicckness, solid FE EP Line Speed
S 305 mpm (1000 fpmm)
w deemed unpprocessable at a meager outpuut of 20 meterss /
was Tip 0.6335 mm (0.025”)
m
minute (65 fpm)). Figure 5 furth
her demonstratess the rationale forf Die Diameter
D 0.8889 mm (0.035”), 3.175
thhe slow runningg speeds whereinn the pressures inn psi for solid FE
EP mm (0.125”) land leength
reached uncomfoortable and unsu ustainable levells of nearly 6,0000

 
International Wire & Cable Symposium 145 Proceedings of the 59th IWCS/IICIT
4. Conclusions
The chemical foaming of FEP results in viscosity modification to
the polymer. This allows for an extended processing range before
exceeding the critical shear stress at the wall which results in melt
fracture. The plasticization of the polymer melt also lowers the
pressure drop in the system which ultimately yields to higher
throughput rates. The data presented in this paper show that
pressure extrusion of chemically foamed FEP is a practical
alternative to tubing extrusion and an enabling technology for
high speed thin walled LAN cables. It should also be noted that
optimized tooling is critical to achieving successful processing in
a pressure application. The pressure extrusion will ultimately lead
to higher line speeds and better performance since there is no risk
of cone breaks.
International Wire & Cable Symposium
5. References
[1] R. B. Bird, W. E. Stewart and E. N. Lightfoot, “Transport
Phenomena”, John Wiley & Sons, New York, p. 53 (1960).
[2] C. Rauwendaal, “Polymer Extrusion”, Hanser Publishers,
New York, p. 316 (1986).
[3] Gendron, Richard, “Thermoplastic Foam Processing:
Principles and Development”, S.T. Lee, Editor, CRC Press,
Boca Raton, FL, pp. 43-97 (2005).
[4] L. Zirkel and H. Münstedt, “Influence of Different Process
and Material Parameters on Chemical Foaming of
Fluorinated Ethylene Propylene Copolymers”, Polymer
Science and Engineering, Wiley Interscience, pp 1740-1749,
(2007).
* - Tyco Electronics, Greensboro, NC
146 Proceedings of the 59th IWCS/IICIT