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Energy is a fundamental part of our everyday lives and plays an essential role in global economic growth. Although most of today’s energy needs are met through the consumption of non-renewable resources such as oil, coal, natural gas, and nuclear sources, there is an increased emphasis on utilizing renewable resources such as biomass, geothermal, hydroelectric, solar, and wind energies.
For more than 50 years, Zeus has supplied polymer solutions to advance renewable and non-renewable technologies that meet new design challenges or require new materials. Many of these materials such as PEEK, PTFE, FEP, and PFA are well known in the energy industry as insulation materials of choice due to their chemical and temperature resistance. New materials are beginning to emerge as new challenges require materials to meet ever more extreme conditions. Below is a brief overview of the polymer solutions we provide to various segments in the energy sector.
Motors, generators, and other electromechanical systems are only as good as the materials used to build them. Zeus offers insulated wire made from various materials such as PEEK, PFA, FEP, and more that protect conductors against elevated temperatures, chemicals, and abrasion.
Heat Shrink Technology
Wire and cable applications often require splicing, and engineers are finding that Zeus PEEKshrink™ and PTFE / FEP Dual-Shrink™ are excellent alternatives to splicing tapes, soldering, or welding. These heat shrinks reduce electrical failures commonly experienced at the splice and increase the speed of the manufacturing process. PEEKshrink™ and Dual-Shrink™ improve the reliability of the spliced joint due to their excellent electrical, chemical, and thermal properties. Zeus also offers more standardized products with varying shrink ratios such as our PTFE 2:1 and 4:1; and FEP 1.3:1 and 1.6:1.
Fiber Optics Solutions
In addition to our American Wire Gauge (AWG) and fractional catalog tubing sizes, we extrude multi-lumens and custom profiles which enable engineers to explore new designs and concepts. Our latest technology is extruding polymer coatings over optical fiber from resins such as PEEK, PFA, and ETFE. Zeus has optimized our coating process to stabilize PEEK during extreme temperature fluctuations. This allows the optical fiber to retain the benefits of PEEK without attenuation-inducing compression during temperature changes.
Want to learn how our polymer solutions can help your team continue growing the energy sector? Contact our team or call toll-free in the US 1-800-526-3842 or +1-803-268-9500 internationally to get free prototype samples today.
Battery Pack Encapsulation – Performance heat shrinks are commonly used to encapsulate battery packs. FEP is often the solution of choice, but we offer other heat shrink options including PEEKshrink™, PFA, and PET. These heat shrinks help protect the battery pack from moisture and chemicals while providing an additional thermal barrier.
Core Sampling Encapsulation – For the oil and gas industry, Zeus has a number of heat shrinks made from PEEKshrink™, FEP, and PFA that allow customers to insulate core samples and apply a durable skin or jacket that is chemically inert. These heat shrinks keep core samples intact for later analysis.
Electrical / Wire Splicing – For protecting your electrical components from extremes of heat, shock, moisture, abrasion, and other environmental conditions, Zeus offers an extensive line of high-temperature insulation products. Our insulated wires are used in electromechanical applications such as electric motors, generators, transformers, and solenoids. We also offer multiple heat shrink options for splicing to eliminate labor-intensive films and numerous tape turns.
Fiber Optic Jacketing – Zeus extrusions can be applied directly over critical optical fibers to provide protection and increase abrasion resistance. Furcation tubing easily slides over optical fibers without damaging the delicate devices while decreasing strain and friction. Multi-lumen tubing allows multiple channels through which fibers can be inserted into a single outside diameter tubing. We also provide engineered surface options which reduce friction and drag force.
Heat Shrink – Zeus heat shrink technology protects items subjected to the extremes of heat, corrosion, shock, moisture, and other environmental conditions.
Slot Liner Insulation – For motor building, we offer round tubing or extruded profiles in a range of materials that can be used for ground wall and slot liner insulation. Annealing options are available to increase dimensional stability at high temperature ranges.
Wire Harness / Cable Assembly – Zeus custom extrusions (Multi-Lumen, Engineered Surface tubing, and PEEK insulated wire) reduce vibration impact, provide high dielectric insulation, and offer protection from harsh environments. In addition to their insulating capabilities, these low friction and light weight tubings are available in spiral cut and convoluted forms for cable wrap.
Customized Extrusion – We routinely provide custom profile and multi-lumen extrusions in a variety of resins. We can create spline shapes commonly used to center wiring, reduce vibration impact, and allow air and moisture passage. Specialized shapes can provide individual isolation of wires in multiple lumens. Spiral wrap and convoluted tubing provide stability and abrasion resistance for wire harnessing applications.
Customized Tubing – We provide round tubing, Lay-Flat™ tubing, and extruded profiles in a variety of resins. Several of these materials can be used for ground wall and slot liner insulation. Annealing options are available to increase dimensional stability at high temperature ranges.
Heat Shrink – These products provide a proven method for applying a tight, protective shrink-to-fit covering to items subjected to extreme heat, corrosion, shock, moisture, and other environmental conditions. We manufacture high-performance heat shrink tubing from a variety of polymer resins. Our heat shrink products perform in both high and low temperature applications with expansion ratios up to 4:1.
PEEK Insulated Wire – Also referred to as magnet wire, this product has excellent dielectric strength of approximately 3,000 V/mil* and continuous service temperature of 500 °F (260 °C). Used in electric motors, generators, transformers, solenoids, and other electromechancial equipment, this material offers superior abrasion resistance and the capability to tolerate moisture. PEEK-coated magnet wire enhances motor performance, and we can insulate many different wire types with PEEK including: solid copper; plated tin, silver or nickel; stranded, square, or rectangular profile wires; stainless steel, and other custom wire types. Additional wire coatings such as PTFE, PFA, ETFE, or FEP are also available.
*Dielectric strength results are dependent upon wall thickness.
PEEKshrink™ – Featuring all of the benefits of PEEK polyment, PEEKshrink™ is PEEK taken to an entirely new level of performance. This advanced product provides a “shrink-to-fit” layer of protection for environmentally sensitive or critical components. The polymer’s inherent purity and lubricity make it a prime choice for applications such as wire coating for medical devices, electronics, telecommunications hardware, and oil exploration equipment. PEEKshrink™ is ideally suited for challenging environments where abrasion, intense pressure, chemicals, water, or dielectric interference pose a threat to wires and electrical components. Like PEEK tubing, this alternative to traditional fluoropolymer protective coatings allows a continuous service temperature of 500 °F (260 °C) and extends the life of the protected components. PEEKshrink™ adheres to metals and is available in colors.
PTFE / FEP Dual-Shrink™ – This specialty product is constructed with an exterior of PTFE heat shrink and an inner layer of FEP. Our Dual-Shrink™ provides a tight, moisture-resistant bond over wires, cables, connectors, splices, terminals, and other components. The PTFE shrinks tightly over inserted parts when the covered section is heated, while the FEP melts and flows into a solid or near-solid encapsulation with a tight fit to withstand stresses involving pull or vibration. This non-flammable tubing has found widespread use in the aerospace, medical, oil and gas, automotive, and electrical industries. PTFE / FEP Dual-Shrink™ has a service temperature of up to 450 °F (232 °C).
Specialized Extrusions – At Zeus, we strive to maintain machine grade tolerances (~0.001″ / 0.025 mm) on plastic tubing used in fiber optics. We provide multiple performance extrusions for fiber optic coatings for use up to 500 °F (260 °C). Our engineered surface options can reduce friction and drag force on tubing used for sheathing. We can also coat fiber optics with an engineered surface option. Fillers such as glass, can be introduced to reduce elongation and promote bondability of the tubing. Aeos™ expanded PTFE (ePTFE) can be used as a cable binder to maximize flexibility while reducing signal loss from microbends.
ETFE – Ethylene tetrafluoroethylene provides excellent impact, abrasion, and stress cracking resistance. This copolymer possesses superior toughness, stiffness, and durability, all while being chemically inert. The material can be extruded in variety of forms including flexible convoluted tubing that meets Mil Spec 81914 certification. ETFE maintains its mechanical properties up to a continuous working temperature of more than 298 ºF (148 ºC). In heat shrinkable form, ETFE has a lower recovery temperature than most polymers. ETFE’s excellent dielectric strength makes it a great material for wire harnessing, splicing aids, or as a protective jacketing. ETFE is gamma sterilizable, Class VI biocompatible, has excellent resistance to stress cracking, and is available in colors.
FEP – This melt processable fluoropolymer allows for long, continuous lengths and has several distinct advantages over PTFE. FEP is preferred for areas that require more optical clarity and flexibility. This fluoropolymer can be manufactured as heat shrink and convoluted products that meet 23053/11 and 81914 Mil Spec certifications, respectively. The material has low gas permeability, possesses an excellent UV transmission rating, and is gamma sterilizable with an operating temperature of 400 °F (204 °C).
HP PFA – High Purity (HP) PFA is chemically nonreactive, ionic resistant, and has a high service temperature. This high purity polymer exceeds the stringent requirements of the SEMI F57 specification. The unique molecular structure of HP PFA reduces chemical extractables. This material also is flame resistant and has low gas permeability. HP PFA has a maximum working temperature of 500 °F (260 °C).
PEEK – This linear, semi-crystalline aromatic polymer is considered the highest performing thermoplastic material due to its ability to withstand extreme temperatures, high pressure, and caustic fluids. This engineered material is a very rigid plastic with excellent lubricity, purity, and amazing strength. PEEK can be used as an alternative to other materials including aluminum, steel, glass, and other polymers. Tubing made from PEEK is lightweight and capable of sustained operating temperatures of 500 ºF (260 ºC). PEEK tubing is also biocompatible, able to withstand high burst pressures, thermoformable; resistant to gamma radiation, wear, and impact; and possesses exceptional torsion stability.
PFA – This fluorinated material is well recognized for its ability to maintain mechanical integrity in extreme temperatures even when exposed to caustic chemicals. Zeus also offers PFA in high purity versions (HP PFA) that are SEMI F-57 certified lending themselves to critical fluid transport tubing applications that demand a very low level of extractables. This fluoropolymer possesses the ability to withstand temperature environments of up to 500 ºF (260 ºC) and can be extruded in convoluted tubing forms that provide a highly flexible conduit. PFA has excellent lubricity, clarity, and flexibility, making it a popular choice for semiconductor, chemical, oil and gas, aerospace, automotive, pharmaceutical, fiber optics, and medical industries.
PTFE – Polytetrafluoroethylene is often referred to as the gold standard for tubing in many industries because of it superior lubricity, high temperature utilization, chemical resistance, and biocompatibility. Zeus can extrude PTFE with precision tolerances. This tubing provides the lowest coefficient of friction of any polymer; it can be manufactured into heat shrinks and convoluted tubing that are 23053/12 and 81914 Mil Spec certified, respectively. Zeus provides PTFE in many forms including extruded tubing, Sub-Lite-Wall™ tubing, heat shrink, special profiles, monofilament, and multi-lumen tubing.
PVDF – Polyvinylidene fluoride delivers high performance at a competitive cost. This polymer tubing, also known as Kynar®, is ideal for a variety of applications which involve extreme conditions. PVDF is characterized by low permeability as well as strong abrasion and chemical resistance. You will find PVDF frequently used in critical fluids transfer, aerospace, oil and gas exploration, automotive, semiconductor, electrical, fiber optics, and medical arenas. PVDF has a good performance-to-cost ratio. PVDF possesses a host of properties that make it useful in a variety of applications that need flexibility without sacrificing performance. PVDF tubing has a working temperature of -58 °F (-50 °C) to 302 °F (150 °C), is resistant to nuclear radiation, has low smoke and flame properties, is resistant to bacterial and fungal growth, and has excellent dielectric properties.