Communication Cable Flame Retardant Aggregate Control
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Solution Overview
Problem
The formation of aggregates from flame retardant auxiliaries in communication cables leads to spatial ununiformity of material properties, instability of communication properties, and reduced productivity, particularly in high-temperature environments, due to the use of halogenated flame retardants and antimony trioxide in olefin-based polymers.
Innovation Solution
A communication cable with a resin composition containing a brominated flame retardant and a flame retardant auxiliary with an aggregate diameter of 50 μm or less, where the flame retardant auxiliary is dispersed as a masterbatch to prevent coarse aggregate formation, ensuring stable communication properties and heat resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a flame retardant auxiliary containing antimony trioxide is added to achieve sufficient flame-retardant effect, then flame retardancy is improved, but aggregate formation occurs causing spatial ununiformity of material properties and instability of communication properties
Solution Approach 1:
The patent applies preliminary action by pre-dispersing the flame retardant auxiliary (antimony trioxide) in a carrier resin to create a masterbatch before final compounding. This preliminary dispersion prevents direct contact and aggregation between antimony trioxide particles during the extrusion process, thereby maintaining spatial uniformity of material properties while achieving the required flame retardancy.
Solution Approach 2:
The patent uses a carrier resin as an intermediary substance between the flame retardant auxiliary (antimony trioxide) and the polymer matrix. The carrier resin acts as a mediator that disperses and distributes the antimony trioxide particles uniformly, preventing direct aggregation and ensuring homogeneous material properties throughout the communication cable insulation.
2Reliability
If conventional flame retardant composition is used to achieve flame retardancy, then flame-retardant effect is improved, but productivity of communication cable manufacturing decreases
Solution Approach 1:
The patent applies preliminary action by pre-dispersing the flame retardant auxiliary (antimony trioxide) in a carrier resin to create a masterbatch before final compounding. This preliminary dispersion prevents direct contact and aggregation between antimony trioxide particles during the extrusion process, thereby maintaining spatial uniformity of material properties while achieving the required flame retardancy.
Solution Approach 2:
The patent improves manufacturing productivity by eliminating the formation of coarse aggregates that would require rework or rejection. The masterbatch approach ensures uniform dispersion from the start, preventing defects that would slow down production and allowing continuous manufacturing at optimal speeds.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution stabilizes communication properties and enhances heat resistance by preventing aggregate formation, maintaining uniform material properties, and improving manufacturing productivity.
Implementation Method 1
a flame retardant auxiliary containing antimony trioxide, wherein an aggregate containing the flame retardant auxiliary has an aggregation diameter of 50 μm or less
Data Source
AI summary
Provided are a communication cable that includes a resin composition formed by adding a halogenated flame retardant and a flame retardant auxiliary to an olefin-based polymer and is excellent in stability of the communication properties and heat resistance, a wire harness that includes such a communication cable, and a manufacturing method according to which such a communication cable can be manufactured with high productivity. A communication cable 1 includes a signal wire 10 constituted by a pair of insulated wires 11 each having a conductor 12 and an insulating coating 13 covering the outer circumference of the conductor 12, and an insulating external layer 20 covering the outer circumference of the signal wire 10. The characteristic impedance is within a range of 100±10Ω.