Fluororesin Foam Composition for Uniform In-Vehicle Wire Insulation

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Solution Overview

Problem

Conventional foam nucleating agents with low pyrolysis temperatures and melting points fail to effectively function in high-melting point fluororesins, leading to issues like coloring, gas generation, enlarged cell sizes, and deteriorated electric characteristics during the molding process, making it difficult to achieve both physical properties and foam characteristics simultaneously.

Innovation Solution

Incorporating a compound with a pyrolysis temperature of 300°C or higher and a solubility parameter of 8 to 15, such as aromatic phosphoric acid esters or amide groups, into a fluororesin-based foam molding composition to enhance foaming efficiency and maintain excellent characteristics even at high molding temperatures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional foam nucleating agents with low pyrolysis temperatures are used in high-melting point fluororesins, then the molding process can be completed, but coloring occurs, gas is generated, cell sizes are enlarged, and electric characteristics deteriorate

Engineering Contradiction:

Improvefoam characteristicsVSAvoidcoloring, gas generation, cell enlargement

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent changes the key parameter of the foam nucleating agent from low pyrolysis temperature to high pyrolysis temperature (300°C or higher). This parameter change allows the nucleating agent to withstand the high molding temperatures of fluororesins without decomposing, thereby preventing coloring, gas generation, and cell enlargement while maintaining reliable foam characteristics.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite system by combining fluororesin with a specifically selected foam nucleating agent that has complementary properties (high pyrolysis temperature and appropriate solubility parameter). This composite material approach ensures both the base resin and nucleating agent are compatible and can function together without adverse reactions.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If conventional foam nucleating agents are used, then the molding process can proceed, but surface irregularities and enlarged cell sizes occur

Engineering Contradiction:

Improvemolding processabilityVSAvoidcell size uniformity, surface quality

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent adjusts the solubility parameter of the foam nucleating agent to fall within the specific range of 8 to 15. This parameter optimization ensures proper dissolution and distribution in the fluororesin matrix, enabling uniform cell formation and smooth surface quality while maintaining ease of manufacture.

Inventive Principle:

Principle #35Parameter changes

3Temperature

If high-melting point fluororesins are used, then heat resistance is improved, but conventional nucleating agents fail to function effectively

Engineering Contradiction:

Improveheat resistanceVSAvoidnucleating agent effectiveness

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The patent selects a foam nucleating agent with a pyrolysis temperature of 300°C or higher, which matches and exceeds the processing temperature requirements of high-melting point fluororesins. This ensures the nucleating agent remains stable and effective throughout the molding process, maintaining reliability while achieving the desired heat resistance.

Inventive Principle:

Principle #35Parameter changes

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 a foam molded body with improved heat resistance, uniform cell formation, and reduced surface irregularities, while maintaining superior electric properties, addressing the limitations of conventional nucleating agents in high-melting point fluororesins.

Implementation Method 1

a foam molding composition which comprises a fluororesin (A) and a compound (B) having a pyrolysis temperature of 300° C. or higher and a solubility parameter (SP value) of 8 to 15

Methodology Applied

Scientific EffectFoam nucleation: Nucleation

Implementation Method 2

a compound (B) having a pyrolysis temperature of 300° C. or higher

Methodology Applied

Scientific EffectPyrolysis: Pyrolysis

Data Source

PatentUS20250316404A1Foam molding composition, foam molded body, foamed electric wire, method for producing foam molded body, method for producing electric wire and in-vehicle network cable

Publication Date: 2025.10.09 DAIKIN INDUSTRIES LTD

AI summary

A foam molded body and a foamed electric wire which can suitably be used as an electric wire for an in-vehicle network cable. A foam molding composition which includes a fluororesin (A), and a compound (B) having a pyrolysis temperature of 300° C. or higher and a solubility parameter (SP value) of 8 to 15, and is to be used for a covering of the electric wire for an in-vehicle network cable.