Flat Cable Insulating Layer Vinyl Chloride Resin Composition
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Solution Overview
Problem
Existing flat cables face a trade-off between reducing thickness for space-saving and maintaining wear resistance and low temperature resistance, as thinner insulating layers with vinyl chloride-based resins often compromise on these properties.
Innovation Solution
A vinyl chloride-based resin composition with polyvinyl chloride, plasticizer, stabilizer, filler, and processing aid is used, with specific ranges for brittle temperature, hardness, and heating deformation, to create a thinner insulating layer that balances wear resistance and low temperature resistance, while maintaining flexibility and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If the thickness of the insulating layer is decreased to achieve space-saving, then the thickness is reduced, but wear resistance of the insulating layer deteriorates
Solution Approach 1:
The patent changes the chemical composition parameters of the vinyl chloride-based resin, specifically controlling the average degree of polymerization (700-3000), plasticizer content (35-55 parts by mass per 100 parts base resin), and processing aid content (0.1-10 parts by mass per 100 parts base resin). These parameter changes enable the insulating layer to achieve both thinness (0.1-0.2 mm) and sufficient wear resistance through optimized material properties rather than increased thickness
Solution Approach 2:
The patent creates a composite resin system by combining vinyl chloride-based resin with specific proportions of plasticizers and processing aids. This composite material approach allows the insulating layer to achieve multiple properties simultaneously: flexibility from plasticizer, processability from processing aid, and balanced wear resistance with low temperature resistance in a thin configuration
2Reliability
If the content of plasticizer is decreased to harden the insulating layer, then wear resistance is enhanced, but low temperature resistance deteriorates
Solution Approach 1:
The patent optimizes the plasticizer content to a specific range (35-55 parts by mass per 100 parts base resin) rather than using extreme values. This parameter optimization achieves a balance where the insulating layer maintains sufficient hardness and wear resistance while preserving flexibility and low temperature resistance, avoiding the trade-off present in conventional approaches
Solution Approach 2:
The patent applies the concept of local quality by creating different functional zones within the insulating layer through controlled composition. The vinyl chloride-based resin provides the base structure for wear resistance, while the plasticizer distributes locally to maintain flexibility and low temperature performance, achieving both properties in different aspects of the same material
3Length of stationary object
If the thickness of the insulating layer is decreased for space-saving, then space is saved, but low temperature resistance may be degraded
Solution Approach 1:
The patent changes the material parameters of the vinyl chloride-based resin, particularly the average degree of polymerization (700-3000) and additive contents, to achieve a thin insulating layer (0.1-0.2 mm) that maintains adequate low temperature resistance through optimized molecular structure and composition rather than relying on thickness
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 achieves a thinner insulating layer with enhanced wear resistance and low temperature resistance, meeting the requirements for space-saving and durability in vehicle wiring while preventing degradation in performance.
Implementation Method 1
polyvinyl chloride with an average degree of polymerization measured by JIS K6720 of from 700 to 3000 as a base resin
Implementation Method 2
a plasticizer, wherein the content of the plasticizer is from 35 parts by mass to 55 parts by mass based on 100 parts by mass of the base resin
Implementation Method 3
a stabilizer
Implementation Method 4
a processing aid, wherein the content of the processing aid is from 0.1 parts by mass to 10 parts by mass based on 100 parts by mass of the base resin
Data Source
Figure 1(a)~1(b)
AI summary
The invention is provided to a flat cable having a thinner insulating covering while keeping sufficient wear resistance and low temperature resistance. The invention provides a flat cable, which includes at least two conductors disposed apart from each other and in parallel to each other, and an insulating covering disposed over a periphery of the at least two conductors, and formed of vinyl chloride-based resin composition having a brittle temperature of from -40 Celsius degrees to -25 Celsius degrees, an hardness D of from 35 to 55, and heating deformation of 10% or below.