Cable Covering Composition Balancing Flame Retardancy and Flexibility
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing cable covering materials for electric vehicles and energy storage systems face challenges in achieving high heat resistance, flame retardancy, and mechanical properties while avoiding halogen-based flame retardants, which are environmentally harmful and degrade flexibility and mechanical properties when excessive amounts of metal hydroxides are used.
Innovation Solution
A polymer composite composition comprising 45% to 70% polyolefin-based resin, 20% to 35% calcium-based flame retardant, 1% to 10% non-halogen-based flame retardant, and 1% to 10% crosslinking agent, with optional additives like styrene-based block copolymer, organosilane, antioxidant, lubricant, and colorant, to create a flexible and heat-resistant resin suitable for cable coverings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If halogen-based flame retardants are used to achieve flame retardancy, then flame retardant performance is improved, but environmental harm increases and mechanical properties deteriorate
Solution Approach 1:
The patent removes halogen-based flame retardants from the composition entirely and replaces them with non-halogen alternatives (metal hydroxides, phosphorus-based, nitrogen-based flame retardants). This extraction of the harmful substance while maintaining the flame retardant function through alternative materials directly resolves the contradiction between flame retardancy and environmental harm.
Solution Approach 2:
The patent employs a composite approach by combining multiple types of non-halogen flame retardants (metal hydroxides, phosphorus-based, nitrogen-based) with polyolefin resin and other additives. This composite material strategy achieves effective flame retardancy without relying on harmful halogen compounds, thus resolving the environmental harm issue while maintaining reliability.
2Reliability
If excessive amounts of metal hydroxide are added to achieve flame retardancy, then flame retardant performance is improved, but flexibility and mechanical properties deteriorate
Solution Approach 1:
The patent merges multiple types of flame retardants (metal hydroxides, phosphorus-based, nitrogen-based) in specific proportions rather than relying on excessive metal hydroxide alone. This combination allows achieving effective flame retardancy with reduced overall filler content, thereby maintaining flexibility and mechanical properties.
Solution Approach 2:
The patent optimizes the proportions of different components, specifically limiting metal hydroxide to 20-40 wt%, phosphorus-based flame retardant to 5-20 wt%, and nitrogen-based flame retardant to 5-20 wt%. These parameter changes in composition ratios achieve flame retardancy without the mechanical property deterioration caused by excessive metal hydroxide addition.
3Object-affected harmful factors
If non-halogen-based flame retardants are used to improve environmental compatibility, then environmental friendliness is improved, but flame retardant performance and mechanical properties may be insufficient
Solution Approach 1:
The patent creates a composite flame retardant system combining metal hydroxides, phosphorus-based, and nitrogen-based flame retardants. This composite approach leverages the synergistic effects of different non-halogen flame retardant mechanisms to achieve UL-1581 VW-1 and JIS C 3005 flame retardant grades, proving that environmentally friendly materials can meet high performance requirements.
Solution Approach 2:
The patent develops a multi-functional polymer composition that simultaneously achieves flame retardancy, heat resistance, flexibility, and environmental compatibility. The composition serves multiple functions (flame retardation through multiple mechanisms, mechanical reinforcement, flexibility maintenance) without relying on halogen-based materials, thus resolving the contradiction between environmental friendliness and performance.
4Object-affected harmful factors
If flame retardant composition is optimized for environmental friendliness, then environmental compliance is improved, but heat resistance and mechanical properties may be compromised
Solution Approach 1:
The patent merges multiple flame retardant types (metal hydroxides, phosphorus-based, nitrogen-based) that work through different mechanisms, creating a synergistic system that achieves both environmental compliance and high heat resistance. The combination allows the composition to satisfy UL-1581 and JIS C 3005 standards while maintaining thermal stability.
Solution Approach 2:
The patent employs a composite material system combining polyolefin resin with optimized proportions of non-halogen flame retardants and other additives. This composite structure achieves environmental compliance through non-halogen materials while maintaining heat resistance and mechanical properties through the synergistic interaction of components.
Data Source
AI summary
A highly heat-resistance and flame-retardant polymer composite composition for cable covering includes a polyolefin-based resin composition, a calcium-based flame retardant, 1% to 10% by weight of a non-halogen-based flame retardant, and a crosslinking agent. The composition exhibits excellent flame retardancy and heat resistance, has excellent flexibility, oil resistance, and processability due to low hardness, and has particularly improved mechanical properties through a special combination of various organic and inorganic materials.