DB44 High-Performance Insulating Plasticizer for Power Cables and Wiring Materials

DB44 High-Performance Insulating Plasticizer for Power Cables and Wiring Materials

What factors determine insulation performance in plasticized PVC cable compounds?Volume resistivity. A plasticizer influences this through its polarity, ionic content, and permanence in the compound; these three factors also determine how the compound performs during aging. DB44 is designed for cable sheathing and insulation formulations requiring stable insulation resistance, heat resistance, and aging performance. It is compatible with conventional 70°C and 90°C cable compound systems. For applications requiring lower temperatures or extended service life, it can be adjusted with DOS, DOA, or TOTM.

Volume resistivity: the metric that determines the grade

Volume resistivity measures how strongly a material resists current flow through its bulk. In plasticized PVC insulation, this property is influenced more by the additive package than by the resin itself. Polar plasticizers, residual catalysts, moisture, and migrating additives all reduce it. A compound that meets specifications when freshly produced may fall out of spec after aging or exposure to hot, humid environments.

DB44 is designed for the first two lines in that table. This makes it suitable for sheathing and insulation formulations rather than for general flexible goods.

Substitution location and manufacturer specifications

Based on manufacturer data, DB44 is evaluated as a replacement direction for DOP/DBP/DOTP in cable granulation at approximately 30% to {2% substitution, with improvements in gloss, volume resistivity, and flame retardancy. These are directional guidelines rather than guarantees; actual results depend on the complete formulation, filler loading, stabilizer system, and your line's extrusion conditions.

A staged substitution is the standard approach: modify part of the plasticizer, conduct a granulation trial, and verify volume resistivity, tensile properties after aging, cold bend performance, and surface quality before proceeding to the next stage. Electrical test results depend on sample preparation and conditioning; therefore, comparisons must always be made between specimens produced and tested under identical conditions.

Meeting 70°C and 90°C ratings, and when to blend

Cable compounds are typically classified by the maximum conductor temperature they can withstand. For a conventional 70°C compound, the plasticizer must maintain its properties throughout the service heat history without significant loss; for a 90°C rating, requirements for volatility and heat aging performance are higher, placing greater demand on the stabilizer system.

Blending is a standard step in cable compound design. Starting from DB44 ensures the base compound already falls within the optimal electrical and aging window, so adjustments refine a strong foundation rather than compensate for weaknesses.

Process notes for granulation and extrusion

Mixing sequence impacts electrical performance more than most formulations anticipate. Add the plasticizer only after the resin is fully wetted to ensure uniform gelation; incomplete gelation creates domains that appear as weak points in resistivity tests and surface defects on extruded insulation. Maintain screw temperature profiles within the stabilizer window, and keep residence time consistent between reference and trial runs to ensure a valid comparison.

Frequently asked questions

Does DB44 replace DOTP one-to-one?No. Substitution is intentional and determined through testing. The published direction for cable granulation ranges from approximately 30% to 70%, with the offset depending on the rest of the formulation.

Which test determines if the compound is acceptable?Volume resistivity, along with the mechanical aging and cold bend tests required by the applicable cable standard for the compound type.

Can DB44 be used in a 90°C compound?Designed for conventional 70°C and 90°C cable compound systems. For higher continuous temperature or extended service life, blending with TOTM is the recommended approach.

Does the plasticizer affect flame retardancy?According to manufacturer data, the substitution direction improves flame retardancy, gloss, and volume resistivity. However, flame performance is primarily driven by the filler and the entire additive package, so verification on the finished compound is required.

Is DB44 available for cable granulation trials?Yes. Samples are available for evaluation, and the trial order MOQ is 1 MT.

Request a sample and recommendation

We can provide a 1kg complimentary testing sample of DB44 shipped worldwide via DHL or FedEx, along with the current technical data for your evaluation. Bulk shipments are loaded as 23 MT flexitank containers from Ningbo or Shanghai, and our team can advise on a phased substitution plan for your granulation line.