Crosslinked Polyolefin Sheath for EV Cable Flexibility
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing cable technologies face challenges in achieving sufficient flexibility and abrasion resistance while maintaining cost-effectiveness, particularly for electric vehicle applications where increased battery capacity requires thicker cables that need to be routed in narrow spaces.
Innovation Solution
A resin composition comprising a copolymer of olefin and a comonomer with polarity, combined with an ethylene-propylene-diene terpolymer, is cross-linked to form a sea-island structure, providing enhanced flexibility and abrasion resistance, and is used as a sheath layer in cables and wire harnesses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If silicone rubber is used as the insulating material, then flexibility and abrasion resistance are improved, but material cost and manufacturing complexity increase
Solution Approach 1:
The patent uses a composite material system consisting of polyolefin resin as the base material and polyethylene crosslinking agent as the additive. This composite approach achieves flexibility comparable to silicone rubber while avoiding the need for complex vulcanization equipment and processes, as the crosslinking occurs in-situ during extrusion
Solution Approach 2:
The patent replaces expensive silicone rubber with cheaper polyolefin resin that achieves comparable performance through crosslinking. The crosslinked structure provides durability equivalent to silicone rubber while the base material and process are more cost-effective and easier to manufacture
2Power
If the conductor diameter is increased to reduce charging time, then power transmission capability is improved, but the cable becomes harder to route in narrow spaces
Solution Approach 1:
The patent changes the physical-chemical parameters of the insulating material by introducing crosslinking structure through polyethylene crosslinking agent. This creates a three-dimensional network that provides high elasticity and recovery, allowing the cable to bend sharply and return to its original shape, thus improving routeability in narrow spaces while maintaining adequate conductor diameter for power transmission
3Ease of operation
If the sheath layer thickness is reduced to improve flexibility, then flexibility is improved, but abrasion resistance deteriorates
Solution Approach 1:
The patent creates a composite structure within the sheath layer by combining polyolefin resin with polyethylene crosslinking agent. The crosslinked network provides enhanced mechanical strength and abrasion resistance, allowing the use of thinner sheath layers that maintain both flexibility and durability
Solution Approach 2:
The patent applies crosslinking locally within the sheath layer structure, creating regions of enhanced strength and elasticity distributed throughout the material. This localized reinforcement allows the overall sheath to be thinner while maintaining adequate abrasion resistance
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 resin composition achieves the necessary flexibility and abrasion resistance, allowing for efficient routing in tight spaces while maintaining heat resistance and reducing material costs, comparable to silicone rubber cables.
Implementation Method 1
the resin component is cross-linked
Implementation Method 2
the resin composition has a sea-island structure in which the copolymer of olefin and the comonomer having polarity is a continuous phase, and the ethylene-propylene-diene terpolymer is a dispersed phase
Data Source
AI summary
A resin composition contains a resin component containing a copolymer of olefin and a comonomer having polarity and an ethylene-propylene-diene terpolymer. The resin component is cross-linked and the tensile stress at 19% strain is 2.0 MPa or less. The resin composition has a sea-island structure in which the copolymer of olefin and a comonomer having polarity is the continuous phase, and the ethylene-propylene-diene terpolymer is the dispersed phase.