Polyvinyl chloride (PVC) composites reinforced with calcium carbonate (CaCO 3 ) have gained significant attention as efficient electrical insulating materials owing to their enhanced thermo-mechanical performance, improved durability and cost-effectiveness. In this study, the influence of CaCO 3 loading on the PVC composites as cable insulation was examined. Various formulations (10%–70% CaCO 3 ) and varying lubricant levels were prepared by dry mixing at 110–120 °C, followed by twin-screw extrusion, and then applied to copper conductors. Standard thermoplastic insulation tests, including heat-shock and cold-bend assessments, confirmed excellent structural integrity, without the formation. Water uptake increased marginally with higher CaCO 3 content; however, even at 70% CaCO 3 , the maximum absorption value (0.636 mg/cm 2 ) remained within permissible limits, which confirmed a uniform filler dispersion. Incorporation of CaCO 3 enhanced thermal stability and reduced mass loss during the aging, reflecting improved resistance to thermal degradation. Mechanical testing revealed that the tensile strength increased with 20% CaCO 3 , thereafter declining, while elongation at break decreased progressively with increased filler loading. Unaged tensile strength retention peaked at 93.50% for PVC/20%CaCO 3 , whereas the highest unaged elongation (104%) was recorded for PVC/10%CaCO 3 . These results demonstrate that PVC/CaCO 3 composites maintain robust thermo-mechanical performance even at elevated filler levels, highlighting their potential for electrical insulation applications where material efficiency, performance reliability and economic considerations are critical.
Iqbal et al. (Wed,) studied this question.