Covered Electric Wire Fluororesin Blend Oil Resistance Flexibility
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Solution Overview
Problem
Existing covered electric wires face challenges in maintaining flexibility and oil resistance while avoiding thermal discoloration and molding defects, particularly in high-temperature environments, due to limitations in the proportion of fluororesin blends and potential for reduced flexibility and elongation.
Innovation Solution
A covered electric wire with a melt-moldable resin composition comprising a fluorinated elastomer and fluororesin blend, where the fluorinated elastomer is dispersed in the fluororesin to achieve specific physical properties such as low volume change in automatic transmission fluid, high melting point, and controlled tensile elongation, ensuring flexibility and oil resistance without thermal discoloration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the proportion of E-TFE copolymer (fluororesin) blended with TFE-P copolymer (fluorinated elastomer) is increased to improve oil resistance, then oil resistance is improved, but flexibility and elongation decrease
Solution Approach 1:
The patent applies parameter changes by precisely controlling the blend ratio of E-TFE copolymer to at most 40 mass% (and preferably 30 mass% or less) to optimize the balance between oil resistance and flexibility. This quantitative parameter control resolves the contradiction by identifying the optimal threshold where both requirements are satisfied simultaneously.
Solution Approach 2:
The patent uses composite materials by blending E-TFE copolymer and TFE-P copolymer in specific proportions to create a resin composition that exhibits both oil resistance and flexibility. The composite structure allows the material to inherit beneficial properties from both components while mitigating their individual drawbacks.
2Strength
If the proportion of E-TFE copolymer (fluororesin) is increased to improve cut-through property, then cut-through property is improved, but flexibility and elongation decrease
Solution Approach 1:
The patent applies parameter changes by controlling the E-TFE copolymer content at at most 40 mass% to balance cut-through property and flexibility. This parameter optimization ensures that the material maintains sufficient toughness and heat resistance while preserving the necessary flexibility for wire harness applications.
3Strength
If fluorinated elastomer and fluororesin are blended to improve mechanical properties, then mechanical properties are improved, but thermal discoloration occurs
Solution Approach 1:
The patent applies parameter changes by controlling the blend composition and processing parameters to minimize thermal discoloration. By optimizing the E-TFE copolymer content and processing conditions, the patent achieves good mechanical properties while suppressing thermal degradation and discoloration during molding and service.
4Strength
If fluorinated elastomer and fluororesin are blended to improve mechanical properties, then mechanical properties are improved, but molding defects occur
Solution Approach 1:
The patent applies parameter changes by optimizing the blend ratio of E-TFE copolymer to at most 40 mass% and controlling processing parameters to achieve good moldability. This parameter optimization prevents molding defects such as weld lines and ensures high-quality molded products with good mechanical properties.
Data Source
AI summary
A covered electric wire has a core wire and a covering material made of a composition applied around the core wire. The covering material is a melt-moldable resin composition. The resin composition may be a fluororesin composition that includes a fluorinated elastomer and a melt-moldable fluororesin. The fluorinated elastomer can be dispersed in the fluororesin. The resin composition has a volume change after being immersed in an automatic transmission fluid at 165° C. for 70 hours of at most 10%, flexural modulus of at most 200 MPa, a rate of the change in tensile elongation after 2,000 hours of a thermal exposure test in the air at 200° C. of at most 30%, and a melting point of at least 215° C.