Low-Crystallinity Ethylene Copolymer Cable Insulation
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Solution Overview
Problem
Conventional crystalline polyethylene-based insulation materials for electric cables face challenges in flexibility, installation difficulty, and safety due to high crystallinity, leading to deformation and electrical issues when installed in narrow spaces, and require lengthy crosslinking processes.
Innovation Solution
A non-crystalline ethylene-alpha olefin copolymer-based insulation material with a melting point of 30° C. to 90° C., combined with 0.5 to 20 parts by weight of a crosslinking agent, is used to provide flexibility and maintain mechanical properties, allowing for in-line crosslinking under high temperature and pressure conditions without deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If crystalline polyethylene-based insulation material is used to ensure tensile strength and electrical properties, then mechanical strength and electrical characteristics are improved, but flexibility deteriorates and installation difficulty increases
Solution Approach 1:
The patent changes the crystallinity parameter of the polyethylene insulation material from high (conventional) to low (5-30% crystallinity). This parameter change enables the material to maintain adequate tensile strength while dramatically improving flexibility and reducing installation difficulty in narrow spaces.
Solution Approach 2:
The patent creates a composite structure by combining low-crystallinity polyethylene with specific crosslinking agents (silane compounds or peroxides) and fillers (such as alumina trihydrate). This composite approach maintains mechanical strength through the crosslinked network while the low-crystallinity base provides flexibility.
2Productivity
If in-line crosslinking is performed under high temperature and pressure to improve production efficiency, then productivity is improved, but insulation deformation occurs due to melting
Solution Approach 1:
The patent changes the melting point parameter of the polyethylene insulation material to a lower range (70-110°C) through reduced crystallinity. This enables the insulation to withstand in-line crosslinking temperatures without deforming, as the crosslinking process occurs at temperatures below the insulation's melting point.
Solution Approach 2:
The patent applies preliminary crosslinking to the insulation material before the final cable assembly crosslinking process. This preliminary crosslinking creates a stable network that prevents deformation during subsequent high-temperature processing steps, ensuring shape stability while maintaining productivity.
3Manufacturing precision
If batch crosslinking is used to prevent insulation deformation, then manufacturing precision is improved, but production time increases significantly
Solution Approach 1:
The patent changes the thermal parameters of the insulation material (lower melting point through reduced crystallinity) to enable continuous in-line crosslinking processes. This eliminates the time-consuming batch processing steps while maintaining shape stability, dramatically reducing production time.
4Temperature
If high crystallinity polyethylene is used to ensure heat resistance, then temperature resistance is improved, but flexibility and elasticity deteriorate
Solution Approach 1:
The patent creates a composite material system where low-crystallinity polyethylene provides flexibility while crosslinking agents (silane or peroxide) and fillers provide heat resistance. The crosslinked network structure maintains thermal stability without requiring high crystallinity, thus preserving flexibility.
Solution Approach 2:
The patent changes the crystallinity parameter to a low range (5-30%) while compensating for heat resistance through crosslinking density and filler content. This parameter change enables the material to maintain heat resistance adequate for cable applications while dramatically improving flexibility and elasticity.
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 results in electric cables with improved flexibility, reduced installation difficulties, and enhanced electrical properties, including higher tensile strength and elastic modulus, while minimizing thermal deformation and maintaining insulation characteristics.
Implementation Method 1
a crosslinking agent, 0.5 to 20 parts by weight based on 100 parts by weight of the ethylene copolymer
Implementation Method 2
the copolymer is a polymer with a melting point of 30° C. to 90° C.
Data Source
AI summary
An insulation material for electric cables includes an ethylene-alpha olefin copolymer with a melting point of 30° C. to 90° C.; and 0.5 to 20 parts by weight of a crosslinking agent based on 100 parts by weight of the ethylene-alpha olefin copolymer. The insulation material composition is based on a non-crystalline ethylene copolymer, and thus is flexible and satisfies tensile strength and insulation characteristics in conformity with the industrial standards. The insulation material composition is suitable for an insulation of electric cables for power, control and signaling that are installed in narrow spaces, in particular, electric cables for ships.