Halogen-Free Flame Retardant Elastomeric Wire Insulation
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Solution Overview
Problem
Conventional insulated wires for electronic equipment face challenges in achieving a balance between flame retardancy, mechanical properties, and consumer appeal, with existing materials posing environmental concerns and limiting recyclability, while also requiring high heat resistance and flexibility.
Innovation Solution
A halogen-free flame retardant elastomeric composition comprising styrenic block copolymers, olefinic thermoplastic elastomers, and specific metal salts or diphosphinic acids, which provides enhanced flame retardancy, mechanical properties, and consumer appeal by optimizing the proportion of components to achieve compliance with UL standards and improved flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If halogen-free flame retardant systems comprising metal hydrate and red phosphorous are used, then flame retardancy is improved, but mechanical properties are jeopardized and toxic fumes are produced when burned
Solution Approach 1:
The patent removes red phosphorous from the flame retardant system, extracting the harmful component while maintaining flame retardancy through alternative means (metal hydrate combined with other non-toxic additives), thus eliminating toxic fume production during combustion
Solution Approach 2:
The patent converts the harmful effect of phosphorous combustion into a beneficial outcome by replacing it with a flame retardant system that achieves equivalent or superior flame resistance without producing toxic fumes, turning the original harm (toxicity) into a benefit (environmental safety)
2Temperature
If crosslinking methods (electron beam or chemical) are used to achieve heat resistance, then heat resistance is improved, but recyclability is limited and manufacturing cost increases
Solution Approach 1:
The patent employs a thermoplastic polymer composition that can be repeatedly processed and recycled without degradation of properties, replacing the need for crosslinked (thermosetting) materials. This allows the material to be melted and reformed multiple times, enabling recyclability while maintaining adequate heat resistance for the application
Solution Approach 2:
The patent achieves heat resistance through careful selection and formulation of thermoplastic polymers with appropriate melting points and thermal stability, rather than through crosslinking. By changing the material parameters (polymer type, molecular weight, composition ratios), the material attains sufficient heat resistance while remaining thermoplastic and recyclable
3Temperature
If high proportion of resin such as polypropylene is used to achieve heat resistance, then heat resistance is improved, but flexibility deteriorates and surface whitening occurs when bent
Solution Approach 1:
The patent uses a composite polymer composition combining multiple thermoplastic polymers (including but not limited to polypropylene) with specific ratios and types. This composite approach allows the material to achieve heat resistance from the crystalline polymers while maintaining flexibility through the amorphous polymer phases, preventing surface whitening when bent
Solution Approach 2:
The patent creates different phases within the polymer composition with distinct properties: crystalline regions provide heat resistance and structural stability, while amorphous regions provide flexibility and prevent surface whitening. This local differentiation of material properties within the composite enables simultaneous achievement of heat resistance and flexibility
4Ease of manufacture
If conventional PVC compounds with plasticizer and heavy metal stabilizer are used, then processing ease is improved, but environmental pollution occurs when discarded
Solution Approach 1:
The patent removes harmful substances (plasticizers and heavy metal stabilizers) from the polymer composition, extracting the environmentally harmful components while maintaining processing ease through alternative approaches (using thermoplastic elastomers and conventional thermoplastic processing methods without harmful additives)
Solution Approach 2:
The patent converts the originally harmful PVC compound system into a beneficial environmentally-friendly thermoplastic polymer composition that maintains all necessary processing characteristics while eliminating pollution, turning an environmental hazard into an eco-friendly solution
Data Source
AI summary
The invention relates to an insulated wire for use in electronic equipment, comprising an electrically conductive core and an insulating layer and/or an insulating jacket consisting of a flame retardant elastomeric composition surrounding the electrically conductive core, wherein the flame retardant elastomeric composition comprises a elastomeric polymer selected from the group consisting of styrenic block copolymers, thermoplastic elastomers and combinations thereof; and a metal salt of a phosphinic acid of the formula [R1R2P(O)O]−mMm+ (formula I) and/or a diphosphinic acid of the formula [O(O)PR1—R—PR2(O)O]2−nMxm+ (formula II), and/or a polymer thereof, wherein R1 and R2 are equal or different substituents chosen from the group consisting of hydrogen, linear, branched and cyclic C1-C6 aliphatic groups, and aromatic groups, R3 is chosen from the group consisting of linear, branched and cyclic C1-C10 aliphatic groups and C6-C10 aromatic and aliphatic-aromatic groups, M is a metal chosen from the group consisting of Mg, Ca, Al, Sb, Sn, Ge, Ti, Zn, Fe, Zr, Ce, Bi, Sr, Mn, Li, Na, and K, and m, n and x are equal or different integers in the range of 1-4.