Fluoropolymer Wire Coating Composition for High-Speed Defect-Free Molding

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Solution Overview

Problem

Existing fluorine-containing copolymers struggle with moldability at high speeds, form coatings with defects, and lack sufficient abrasion resistance, water vapor and carbon dioxide permeability, creep resistance, durability to repeated loads, and crack resistance, especially when used in electric wires and coatings.

Innovation Solution

A fluorine-containing copolymer with specific ratios of tetrafluoroethylene, hexafluoropropylene, and perfluoro(propyl vinyl ether) units, optimized for melt flow rates and functional group content, enabling high-speed injection molding and extrusion forming with improved 125°C abrasion resistance, low water vapor and carbon dioxide permeability, and enhanced crack resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a crosslinking catalyst master batch is used during the extrusion step to promote silane-modified polyethylene crosslinking reaction, then crosslinking reaction is enhanced, but resin aggregates are generated and homogeneity of physical properties is lowered

Engineering Contradiction:

Improvecrosslinking reactionVSAvoidhomogeneity of physical properties

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent extracts the crosslinking catalyst application step from the extrusion process. Instead of adding crosslinking catalyst during extrusion, the patent applies crosslinking catalyst after extrusion by coating or immersing the extruded product in a crosslinking catalyst solution, thereby avoiding resin aggregate formation during extrusion while still achieving crosslinking enhancement.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent performs preliminary crosslinking preparation by first extruding the silane-modified polyethylene without catalyst, then subsequently applying the crosslinking catalyst in a controlled manner. This preliminary extrusion step creates a uniform base structure before crosslinking catalyst application, preventing homogeneity issues.

Inventive Principle:

Principle #10Preliminary action

2Stability of the object's composition

If silane-modified polyethylene is extruded and then crosslinked by applying a crosslinking catalyst, then crosslinking can be controlled, but the process requires additional steps

Engineering Contradiction:

Improvecrosslinking controlVSAvoidprocess steps

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The patent merges the crosslinking catalyst application with the extrusion process by using the extrusion machine to both extrude the silane-modified polyethylene and simultaneously apply the crosslinking catalyst in a coordinated manner, reducing the number of separate process steps while maintaining crosslinking control.

Inventive Principle:

Principle #5Merging (Combining)

3Temperature

If conventional polyethylene is used for insulation, then processability is good, but heat resistance is insufficient for high-temperature applications

Engineering Contradiction:

Improveheat resistanceVSAvoidprocessability

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The patent changes the chemical parameters of polyethylene by introducing silane modification, which alters the molecular structure to enable crosslinking. This parameter change enhances heat resistance while the crosslinking process is controlled to maintain good processability during extrusion and installation.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite material system combining silane-modified polyethylene with crosslinking catalyst to achieve both high heat resistance and good processability. The silane-modified polyethylene provides the base polymer matrix with improved thermal properties, while the crosslinking catalyst enables controlled crosslinking to enhance heat resistance further without compromising processability.

Inventive Principle:

Principle #40Composite materials

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 copolymer allows for defect-free, high-speed formation of thin coatings with excellent shape stability and crack resistance, suppressing water vapor penetration and chemical-induced cracking, suitable for electric wires and various applications.

Implementation Method 1

silane-modified polyethylene for insulation which has undergone crosslinking by contact with a crosslinking catalyst

Methodology Applied

Scientific EffectCrosslinking reaction: Chemical Bonding

Implementation Method 2

the injection molded body has a memory effect and can be returned to an initial state before deformation when a predetermined condition such as heating is applied

Methodology Applied

Scientific EffectMemory effect: Shape Memory Polymer

Data Source

PatentEP4299637B1Fluorine-containing copolymer, injection molded body, electric wire covering material and electric wire

Publication Date: 2026.04.08 DAIKIN INDUSTRIES LTD

AI summary

There is provided a fluorine-containing copolymer comprising tetrafluoroethylene unit, hexafluoropropylene unit, and a perfluoro(propyl vinyl ether) unit, wherein the copolymer has a content of the hexafluoropropylene unit of 5.0 to 7.0% by mass with respect to the whole of the monomer units, a content of the perfluoro(propyl vinyl ether) unit of 1.5 to 2.6% by mass with respect to the whole of the monomer units, and a melt flow rate at 372°C of 9 to 40 g/10 min.