Halogen-Free Polymer Resin Composition for Marine Cable Applications
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Solution Overview
Problem
Cables for ships and drillships face challenges in maintaining flexibility at low temperatures, achieving oil resistance, and ensuring flame retardancy while being halogen-free, as existing materials struggle to meet stringent requirements such as IEC 60092-359 and NEK 606, especially with harsher conditions encountered in marine structures like oil well drilling ships.
Innovation Solution
A halogen-free polymer resin composition comprising a polyvinyl acetate resin with 60-80 wt% vinyl acetate, ethylene resin with a polar group, ether-type polyurethane resin, aluminum and magnesium hydrates, flame retardants, antioxidants, plasticizers, and a peroxide-based crosslinking agent, which balances mechanical properties, low-temperature flexibility, and oil resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If ethylene vinyl acetate is used to maintain flexibility at low temperature, then low-temperature flexibility is improved, but oil resistance deteriorates due to poor resistance to aromatic hydrocarbons in IRM 903 oil
Solution Approach 1:
The invention uses a composite material system consisting of polyvinyl acetate resin as base resin, ether-type polyurethane resin as modifier, and ethylene resin with polar groups. This composite structure combines the low-temperature flexibility of ethylene vinyl acetate with the oil resistance of polyvinyl acetate and ether-type polyurethane, achieving both requirements simultaneously.
Solution Approach 2:
The invention specifies precise compositional parameters: polyvinyl acetate resin (100 parts), ether-type polyurethane resin (30-40 parts), ethylene resin with polar groups (10-15 parts), and vinyl acetate content (60-80 wt%). By controlling these parameters within specific ranges, the material achieves optimal balance between low-temperature flexibility and oil resistance.
2Reliability
If halogen-containing compounds are used to achieve flame retardancy, then flame retardancy is improved, but environmental safety deteriorates due to toxic emissions during combustion
Solution Approach 1:
The invention extracts and eliminates halogen-containing compounds from the cable sheath material composition, replacing them with halogen-free alternatives. The base resin uses polyvinyl acetate and ether-type polyurethane without halogens, and flame retardancy is achieved through alternative mechanisms that do not produce toxic emissions during combustion.
Solution Approach 2:
The invention converts the potential harm of flammability into benefit by using halogen-free flame retardant mechanisms. The aluminum hydrate and magnesium hydrate components decompose endothermically during fire exposure, absorbing heat and forming protective char layers that actually enhance fire resistance without producing toxic gases.
3Reliability
If stronger oil resistance is achieved for marine structures, then oil resistance is improved, but material selection becomes more restricted and complex
Solution Approach 1:
The invention creates a universal material composition that simultaneously satisfies multiple stringent requirements: IEC 60092-359 oil resistance, NEK 606 oil resistance (with IRM 903 oil), low-temperature flexibility at -40°C, and halogen-free flame retardancy. The multi-functional ether-type polyurethane resin and polar-group ethylene resin serve multiple purposes: maintaining flexibility, enhancing oil resistance, and improving adhesion.
Solution Approach 2:
The invention introduces ethylene resin with polar groups (10-15 parts per 100 parts base resin) as a specific functional component that locally enhances oil resistance through polar interactions with oil molecules, while the ether-type polyurethane resin provides localized flexibility enhancement. This targeted addition achieves strong oil resistance without requiring complete material system redesign.
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 polymer resin material maintains flexibility at -40°C, satisfies flame retardancy and oil resistance requirements for both general and marine structures, and does not emit toxic substances during combustion, making it suitable for extreme conditions in drillships.
Implementation Method 1
140-170 parts by weight of aluminum hydrate, 15-55 parts by weight of magnesium hydrate and a flame retardant aid
Implementation Method 2
4-5 parts by weight of a crosslinking agent
Data Source
AI summary
The present invention relates to a halogen-free polymer resin composition and a polymer resin material prepared by using said composition, in particular a cable for using in ships or drillships. The polymer resin material prepared by using the composition according to the present invention maintains flexibility even at low temperature of -40°C, and has fire retardant properties required to use in cable for general ships as well as oil resistance properties required to use in marine structures such as oil well drilling ships and oil well drilling structures, or drillships.