PFA-free insulation: silicone as an alternative for our electric heat mats and co.
Silicone is a real alternative to PFA insulation, whether for heating elements, sensor mats and the like.
Sustainability and environmentally friendly solutions are crucial for our production of electric heat mats and the like – which is why we also use wire with PFA-free insulation, among other things. One possible PFA-free alternative for cable insulation is silicone, which offers many advantages and comes closest to PFA in some properties.
What is PFA and why is it used?
PFA (perfluoroalkoxy) is a fluoropolymer that is used in cable insulation because it has excellent chemical and thermal resistance. It is flexible, has a high temperature resistance (up to 260°C) and is resistant to chemicals, solvents and weathering. Due to these properties, PFA is often used in demanding environments such as the aerospace, automotive and chemical industries. Due to the impending possible ban on PFA from 2026, the search for environmentally friendly alternatives is becoming increasingly urgent. The use of wire with PFA-free insulation is therefore a decisive step towards being able to offer environmentally friendly and regulatory compliant solutions in the future. PFA-free insulation fulfills important requirements such as flexibility and electrical conductivity while being more sustainable and safer to handle. Especially in technical embroidery, where materials with high performance requirements are processed, we want to support the transition to more environmentally conscious production with PFA-free wires and at the same time develop sustainable applications.
Why PFA-free insulation?
Environmental concerns and sustainability:
- Fluorine-containing materials such as PFA are harmful to the environment because they are made from synthetic chemicals that are difficult to break down in nature. They can persist in the environment for many years, posing potential risks to wildlife and human health.
- PFA-free materials such as polyolefins or thermoplastic elastomers (TPE) consist of carbon-based polymers that are easier to recycle and less harmful to the environment.
Halogen-free cable insulation:
- Halogens are chemical elements such as fluorine, chlorine, bromine, etc., which can release toxic vapors and corrosive substances during combustion. As PFA contains fluorine, there is a risk of this.
- Halogen-free alternatives release less hazardous gases in the event of fire, which is particularly important in public buildings, transportation and electrical installations to ensure the safety of people.
Mechanical and electrical properties:
- While PFA has good thermal properties, some PFA-free materials offer better mechanical properties, such as higher abrasion resistance or better flexibility, which can be advantageous for certain applications.
- Electrical insulation properties can also be achieved with PFA-free materials such as cross-linked polyethylene (XLPE), which also offers high dielectric strength.
Cost aspects:
- PFA is relatively expensive and its processing requires specialized techniques. The higher material and manufacturing costs can mean that cables with PFA insulation are more expensive than those with PFA-free alternatives.
- PFA-free materials such as polyvinyl chloride (PVC), polyethylene (PE) or polyurethane (PU) are more cost-effective.
Advantages of silicone as cable insulation
High temperature resistance:
✔ Silicone can withstand temperatures from around -60°C to +200°C while remaining flexible. This temperature resistance makes it one of the few PFA-free alternatives that offer similar high-temperature properties to PFA.
Outstanding flexibility:
✔ Silicone is extremely flexible, even at low temperatures, and retains its shape even with repeated movement and bending. This property is advantageous for applications in which cables often have to be moved or bent, such as in robotics or mechanical engineering.
Good electrical insulation properties:
✔ Silicone offers good electrical insulation properties and is sufficient for many applications, especially at low to medium voltages.
Chemical resistance:
✔ Although silicone does not offer quite the same chemical resistance as PFA, it shows good resistance to moisture, UV radiation, oxygen and ozone. It is therefore well suited to outdoor applications and exposure to the elements.
Halogen-free and low smoke emission:
✔ Silicone is halogen-free, which means that it does not release toxic or corrosive gases in the event of fire. It also produces little smoke, which makes it safer for use in public buildings, trains or airplanes.
Further examples of PFA-free alternatives
In addition to silicone, there are other materials that are used in cable insulation and offer different properties, including
Polyvinyl chloride (PVC):
✔ A widely used and cost-effective material for cable insulation.
✔ It has good electrical insulation properties, is flexible and offers protection against the weather.
✔ Disadvantage: PVC is not halogen-free and therefore releases toxic gases in the event of fire.
Polyolefins (PE, XLPE):
✔ Polyethylene (PE) is a thermoplastic material that is well suited for insulating cables.
✔ Cross-linked polyethylene (XLPE) has better thermal resistance and is able to withstand higher temperatures.
✔ These materials are halogen-free and release fewer toxic substances.
Thermoplastic elastomers (TPE):
✔ A material that combines the properties of plastics and rubber, resulting in high flexibility and abrasion resistance.
✔ TPE is halogen-free and is well suited for applications where cables are frequently bent or moved.
Polyurethane (PU):
✔ Offers excellent abrasion resistance, flexibility and resistance to chemicals and oil.
✔ Suitable for demanding applications where mechanical stress and environmental influences play a role.
Customised heating solutions and sensors – produced cost-effectively in Germany
Embro is a manufacturer of heating helements, sensor mats and more for the B2B market. We develop individual solutions for our customers and produce cost-effectively in Germany – for innovative industrial applications in small and large series of between 500 and 100,000 units. Find out more about our heating elements.
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