Plastics Testing

The evaluation of plastic materials may include the determination of material flammability (burning
characteristics), ignition characteristics from various thermal and electrical sources, electrical tracking and
additional electrical characteristics, and analytical tests. Property retention following exposure to long-
term elevated temperature (air-oven aging), water, ultraviolet light, cold, and other outside influences may
also be evaluated.

Properties evaluated by UL include:

Color Concentrates
Components Concentrates
Outdoor suitability program for plastics
UL 746A electrical and mechanical properties
UL 746B thermal-aging program
UL 746C file review
UL 94 flammability
Materials for use in special environments are investigated for specific end-use product applications where
requirements exist for the retention of properties after exposure to certain critical operating and/or
environmental conditions. This includes exposure to various types of ultraviolet (UV) radiation.

Color Concentrates (QMQS2)

When an end-product manufacturer orders a Recognized plastic in a custom color, the Recognized
plastics supplier must stop production, clean the machinery, and proceed with a special run for the
production of this custom-color. This is a time-consuming and costly procedure that is typically reflected in
the cost of the order. In addition, the Recognized plastics supplier may require a large minimum order
unless the order is for a neat natural resin.

The color concentrate category (QMQS2) offers end-product manufacturers faced with these challenges
the option of ordering the necessary amount of the Recognized neat natural resin while also obtaining a
color concentrate Recognized for use with the Recognized plastic. By dry blending the two materials
without exceeding the published maximum let-down ratio, end-product manufacturers can produce the
contracted part, which is typically more cost-effective than ordering a custom Recognized plastic.

Recognition of a color concentrate for use with a vertically rated Recognized base resin is specific and
requires the submittal of standardized test samples. The samples consisting of the color concentrate let-
down into the Recognized base resin are tested to certify that the use of the color concentrate does not
compromise the flame rating of the Recognized base resin. The Recognition of color concentrates
requires submittal and testing for each Recognized vertically rated base resin.

Similarly, Recognition for use with HB-rated Recognized base resins involves the submittal of
standardized test samples of the color concentrate let-down into a Recognized HB-rated base resin for
testing. If this testing does not compromise the HB-flame rating of the Recognized base resin, the newly
Recognized color concentrate has a generic Recognition which permits its use in any Recognized HB-
rated base resin of that particular generic type.

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Component Concentrates (QMLJ2)

A custom-compounding plastics company typically purchases a neat natural resin from a plastics supplier
and enhances that formulation by introducing an additive concentrate package to generate a new
product. This newly Recognized material is tested and published under the component-plastics category
(QMFZ2). The component-concentrates category (QMLJ2) permits the Recognition of the additive
concentrate package that was blended with the Recognized neat base resin to produce the newly
formulated Recognized plastic.

Category QMLJ2 also permits the Recognized base resin to be shipped directly to the Recognized end-
product manufacturing location. The Recognized concentrate package can be shipped directly to the
manufacturer as well. Before molding, resin and package are dry-blended at the specific let-down ratio by
the Recognized manufacturer. For this process, the manufacturer must be Recognized under the
fabricated parts, Recognized molders category (QMMY2).

This method of supplying the base resin gives the end-product company an opportunity for large scale
purchasing and shipment of the base resin. The Recognized concentrate can be ordered and shipped
based on production schedules. This method also provides the plastics supplier with the capability of
large-scale production runs of the base resin rather than custom compounding orders.

In publishing the Recognition for the concentrate, the Recognized concentrate package, Recognized
base resin suppliers name, file number and grade designation are noted on the Recognition card. The
newly formulated Recognized material designation, file number and company name are also noted.

To ensure reproducibility of the Recognized concentrate package, identification testing consisting of

infrared spectroscopy (IR), thermogravinetry (TGA), and differential scanning calorimetry (DSC) testing is
conducted on the Recognized concentrate package let-down into its generic carrier. Periodic testing
under ULs Follow-Up Services program is conducted.

IEC Ball Pressure Temperature (BP)

IEC ball pressure temperature, in accordance with IEC 695-10-2, is expressed as the temperature (in
degrees C) at which a 5-millimeter diameter ball causes a 2-millimeter diameter or less impression on the
material surface.

Outdoor Suitability
A material considered suitable for outdoor use has gone through testing in accordance with UL 746C,
Polymeric Materials, Use in Electrical Equipment Evaluations as follows:
 1. 1,000 hours of xenon-arc weatherometer conditioning
2. Water immersion for seven days at 70 degrees C.
The material is tested for flammability, mechanical impact and mechanical strength before and after
exposure to these conditions. Test results may lead to one of the following outcomes:

(f1) This footnote indicates that the material has met both UV and water exposure or immersion
requirements as called out in UL 746C. The material is suitable for outdoor use with respect to exposure
to ultraviolet light, exposure to water, and immersion in accordance with UL 746C.

(f2) This footnote indicates that the material has only met or has been tested partially for UV or water
exposure or immersion. The material was subjected to one or more of the following tests: UV, water
exposure or immersion in accordance with UL 746C, where the acceptability for outdoor use is to be
determined by UL.

Thermal-aging program
Most materials covered by this program have been investigated with respect to retention of certain critical
properties including dielectric, tensile and impact as part of a longtime thermal-aging program conducted
in accordance with UL 746B, Polymeric Materials, Long Term Property Evaluations.

The end-of-life of a material at each test temperature in this program is assumed to be the time when the
value of the critical property had decreased to 50 percent of its original (as received) value. If a material
has been investigated under the thermal-aging program, the relative temperature index (RTI), in degrees
C, shown is based on a comparison with a material which has acceptable service experience and
correlates numerically with the temperatures above in which the material is likely to degrade prematurely.

If a material has not been investigated under the thermal-aging program, the RTI shown is based on the
generic class of the material. A tabulation of the temperature indices according to the generic material
class is included in UL 746B and is based on the past field-test performance and chemical structure.

More than one RTI may be appropriate for a given material depending on the property requirements for a
specific application. In certain cases, higher temperatures are permitted if so specified by the end-use
product Standard.

Relative temperature index (RTI) is the maximum service temperature for a material where a class of
critical property will not be unacceptably compromised through chemical thermal degradation. This spans
over the reasonable life of an electrical product relative to a reference material having a confirmed,
acceptable corresponding performance-defined RTI.

Electrical RTI is associated with critical electrical insulating properties.

Mechanical impact RTI is associated with critical impact resistance, resilience and flexibility properties.

Mechanical strength RTI ormechanical without impact is associated with critical mechanical strength
where impact resistance, resilience and flexibility are not essential.
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UL 746A Testing
UL 746A TESTING FOR ELECTRICAL PROPERTIES

The following tests determine the electrical properties of polymeric materials:

Dielectric breakdown voltage strength (DS)

Comparative tracking index (CTI)
High voltage tracking rate (HVTR)
High voltage, low current, dry arc resistance D495

UL 746A resistance to ignition of polymeric materials

The following tests determine the resistance to ignition of polymeric materials:

Hot wire ignition (HWI)

High-current arc ignition (HAI)
High voltage arc resistance to ignition (HVTR)
Glow-wire ignitability test (GWIT, GWFI)

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UL 746C
UL 746C, Polymeric Materials, Use in Electrical Equipment Evaluations revision modifications took effect
on June 1, 2004. The following information summarizes the changes and provides additional guidance to
help assist with product development.

Flow Chart For Portable Unattended Household Equipment

Flow Chart For Portable Attended And Unattended Commercial Equipment
Standards Information And Ordering

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UL 94
TESTS FOR FLAMMABILITY OF PLASTIC MATERIALS FOR PARTS IN DEVICES
AND APPLIANCES
There are two pre-selection test programs conducted on plastic materials to measure flammability
characteristics. The first program determines the materials tendency to either extinguish or spread the
flame once the specimen has been ignited. The program is described in UL 94, Tests for Flammability of
Plastic Materials for Parts in Devices and Appliances which is now harmonized with IEC 60707, 60695-
11-10 and 60695-11-20 and ISO 9772 and 9773.

The second program measures the ignition resistance of the plastic to electrical ignition sources. The
materials resistance to ignition and surface tracking characteristics is described in UL 746A, which is
similar to the test procedures described in IEC 60112, 60695 and 60950.

UL 94 Flame Classifications

There are 12 UL 94 specified flame classifications assigned to materials based on the results of these
small-scale flame tests. These classifications, listed in descending order for each of the following three
groupings, are used to distinguish a materials burning characteristics after test specimens have been
exposed to a specified test flame under controlled laboratory conditions.

Six of the classifications relate to materials commonly used in manufacturing enclosures,

structural parts and insulators found in consumer electronic products (5VA, 5VB, V-0, V-1, V-2,
HB).
Three of the remaining six classifications relate to low-density foam materials commonly used in
fabricating speaker grills and sound-damping material (HF-1, HF-2, HBF).
The last three classifications are assigned to very thin films that are generally not capable of
supporting themselves in a horizontal position (VTM-0, VTM-1, VTM-2). These are usually
assigned to substrates on flexible printed circuit boards.
Horizontal versus Vertical Positioning

Specimens molded from the plastic material are oriented in either a horizontal or vertical position
depending on the specifications of the relevant test method. They are then subjected to a defined flame
ignition source for a specified period of time. In some tests, the test flame is only applied once as is the
case in the horizontal burning (HB) test while the flame is applied at least twice in other tests.

An HB flame rating indicates that the material was tested in a horizontal position and found to burn at a
rate less than a specified maximum.

The three vertical ratings V2, V1 and V0 indicate that the material was tested in a vertical position and
self-extinguished within a specified time after the ignition source was removed. The vertical ratings also
indicate whether the test specimen dripped flaming particles that ignited a cotton indicator located below
the sample.

UL 94 also describes a method in which the test flame is applied for up to five applications in testing for a
5VA or 5VB classification. These small-scale tests measure the propensity of a material to extinguish or
spread flames once it becomes ignited.

Difference in Test Methods and Criteria

When looking at flame ratings for plastic materials commonly molded to fabricate enclosures and
structural parts/insulators found in consumer electronic products (5VA, 5VB, V-0, V-1, V-2 and HB), a
material classified as 5VA or 5VB is subjected to a flame ignition source that is approximately five times
more severe than that used in the V-0, V-1, V-2 and HB tests. Also, these specimens may not drip any
flaming particles. Three of the remaining six classifications specified in UL 94 relate to low-density foam
materials commonly used in fabricating speaker grills and sound-deadening material (HF-1, HF-2, HBF).
The remaining three classifications are assigned to very thin films commonly used in flexible printed
wiring boards, generally not capable of supporting themselves in a horizontal position (VTM-0, VTM-1,
VTM-2). A flame rating of VTM-0 cannot be considered equivalent to a V-0 rating, as the test methods are
quite different. Likewise, VTM-1 and VTM-2 cannot be considered equivalent to V-1 and V-2 respectively.

UL 746A Ignition Tests

In addition to flammability considerations, a materials ability to resist ignition from electrical sources is
another important factor that must be considered in the selection and evaluation of a material for use in
electrical equipment. Possible electrical ignition sources in equipment include: overloaded (overheated)
electrical conductors and components; arcing parts, such as the open contacts of switches and relays;
and arcing at broken or loose connections (e.g., splices or terminals). Polymeric materials in direct
contact with or in close proximity to overloaded or arcing electrical parts could ignite.

The three basic tests used to evaluate a materials ability to resist ignition are hot-wire ignition (HWI),
high-current (or high-amp) arc ignition (HAI), and high-voltage arc tracking rate (HVTR). Details regarding
test criteria can be found in UL 746A, Polymeric Materials, Short Term Property Evaluations. The UL iQ
Database tabulates the results of small-scale tests conducted on the materials.

The HWI test determines a materials resistance to ignition when exposed to abnormally high
temperatures resulting from a component failure such as a conductor carrying far more than its rated
current. HWI performance is expressed as the mean number of seconds required to ignite a specimen
when wrapped with an energized non-chrome resistive wire that dissipates a specified level of energy.

The HAI test determines a materials ability to withstand electrical arcing either directly on or just above
the surface of the plastic material. This can occur in the presence of open switch contacts or in the event
of the failure of an electrical connection. HAI performance is expressed as the number of arc rupture
exposures using standardized electrode materials, geometry and electrical supply circuit required to
ignite a specimen when the arc occurs directly on the surface or a specified distance above the surface.

The HVTR for a material is expressed as the rate in inches per minute that a tracking path can be
produced on the surface of the material under standardized test conditions. This test relates to the
establishment of an electrically conductive path on the surface of a solid, insulated material as a result of
electrical stress.

Another ignition test can be applied to measure a materials resistance to ignition property. This test is the
glow-wire ignitability test and is described in UL 746A and UL 746C, Polymeric Materials, Use in Electrical
Equipment Evaluations. The test method is based on a test procedure that is documented in IEC 60695
and specified in numerous IEC end-product specifications including IEC 60335-1. The test is somewhat
similar to the HWI test in that it measures a materials resistance to ignition on application of a heated
non-flaming source.

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