MIL-DTL-442G
3.3 Insulation (classes 1, 2, and 3). The minimum insulation thickness between conductors shall be
.0469 inches (1.19 mm), the maximum insulation thickness surrounding each conductor shall be .0345
inches (.88 mm), and there shall be not less than .013 inch (.33 mm) of insulation at any point on each
conductor. The insulation material shall meet the applicable physical property values specified in table II
and table III accordingly.
TABLE II. Insulation physical properties.
Property
Class 1
Class 2
Class 3
Tensile strength (psi) minimum
1,500
1,200
3,000
1/
1/
300
650
Ultimate elongation (percent) minimum
150
Tension set maximum in inches (mm) (2 inch to
Not applicable
.5 (12.70)
.063 (1.60)
5 inch stretch)
1/ 2.0 inch gauge length.
TABLE III. Insulation physical properties (after aging).
Property
Class 1
Class 2
Class 3
Tensile strength (psi) minimum
Not applicable
900
2,500
1/
1/
195
455
Ultimate elongation (percent) minimum
Not applicable
1/ 2.0 inch gauge length.
3.3.1 Vinyl polymer compound (class 1). The insulation material shall be a black, fungus-resistant
vinyl polymer compound.
3.3.1.1 Heat resistance. The vinyl polymer compound shall not become soft or tacky as determined
by the "blocking test" when exposed to the conditions specified in 4.4.8.1.1.
3.3.2 Synthetic rubber compound (class 2). The insulation material shall be a vulcanized copolymer
of butadiene and styrene or a blend of synthetic and natural rubber.
3.3.2.1 Synthetic rubber compound aging. The insulation material shall meet the physical property
3.3.3 Natural rubber compound (class 3). The insulation material shall be a cured natural rubber.
3.3.3.1 Natural rubber compound aging. The insulation material shall meet the physical property
3.4 Finished cable.
3.4.1 Dielectric strength. The cable shall withstand a potential of 1,000 volts at 60 Hz for a minimum
of one minute duration.
3.4.2 Insulation resistance. The minimum resistance value per 1,000 feet of cable shall be 50
megohms when a dc voltage between 200 to 500 volts is applied for a minimum of one minute duration.
3.4.3 Flexibility. The cable shall be flexible when exposed to temperatures of 40 °C or 55 °C as
applicable for the specified cable grade, and shall show no evidence of cracking, chipping, or other
damage when flexed at this temperature.
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