Halogen-Free Resin Composition for Insulated Wire Flame Retardancy
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Solution Overview
Problem
Halogen-free flame-retardant resin compositions for insulated wires and cables face challenges in achieving balanced mechanical, low-temperature, and electrical characteristics while ensuring sufficient flame retardancy, as high amounts of metal hydroxides required for flame retardancy can compromise these properties.
Innovation Solution
A crosslinkable halogen-free resin composition comprising a polymer blend of maleic anhydride-modified high-density polyethylene, ethylene-acrylic ester-maleic anhydride terpolymer, maleic anhydride modified ethylene-α-olefin copolymer, and ethylene-acrylic ester copolymer, with magnesium or aluminum hydroxide mixed in specific proportions to enhance filler acceptability, adhesion, and dispersibility, thereby maintaining mechanical and electrical properties while providing flame retardancy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large amount of metal hydroxide is added to achieve sufficient flame retardancy, then flame retardancy is improved, but mechanical characteristics, low-temperature properties and electrical characteristics deteriorate
Solution Approach 1:
The patent optimizes the metal hydroxide content to a specific range (120-200 parts by mass per 100 parts by mass of polymer blend) and precisely controls the composition ratios of multiple polymers in the blend. This parameter optimization ensures sufficient flame retardancy while preventing excessive metal hydroxide from degrading mechanical, low-temperature, and electrical properties
Solution Approach 2:
The patent creates a complex polymer blend composite consisting of maleic anhydride-modified high-density polyethylene, ethylene-acrylic ester-maleic anhydride terpolymer, maleic anhydride modified ethylene-α-olefin copolymer, and ethylene-acrylic ester copolymer. This multi-component composite structure allows the materials to complement each other, maintaining mechanical strength and other properties even with high metal hydroxide content for flame retardancy
2Reliability
If a large amount of metal hydroxide is added to achieve sufficient flame retardancy, then flame retardancy is improved, but low-temperature properties deteriorate
Solution Approach 1:
The patent specifies precise composition ratios for each polymer component in the blend, controlling the metal hydroxide content within 120-200 parts by mass per 100 parts by mass of polymer blend. This parameter control ensures flame retardancy is achieved without excessive metal hydroxide that would harm low-temperature properties
Solution Approach 2:
The multi-component polymer blend composite structure allows different polymers to contribute their strengths: maleic anhydride-modified high-density polyethylene provides filler acceptability, while other polymers maintain low-temperature flexibility. This composite approach preserves low-temperature properties despite high metal hydroxide content needed for flame retardancy
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 composition achieves excellent flame retardancy, mechanical characteristics, low-temperature properties, and electrical characteristics, with a balanced performance even after cross-linking, as demonstrated by improved tensile strength, low-temperature bend resistance, and abrasion resistance.
Implementation Method 1
a polymer blend comprises a maleic anhydride-modified high-density polyethylene, 30 to 50 parts by mass of an ethylene-acrylic ester-maleic anhydride terpolymer, 5 to 20 parts by mass of a maleic anhydride modified ethylene-α-olefin copolymer and 10 to 30 parts by mass of an ethylene-acrylic ester copolymer
Data Source
AI summary
A crosslinkable halogen-free resin composition includes a polymer blend, and a metal hydroxide mixed in an amount of 120 to 200 parts by mass per 100 parts by mass of the polymer blend. The polymer blend includes a maleic anhydride-modified high-density polyethylene, 30 to 50 parts by mass of an ethylene-acrylic ester-maleic anhydride terpolymer, 5 to 20 parts by mass of a maleic anhydride modified ethylene-α-olefin copolymer and 10 to 30 parts by mass of an ethylene-acrylic ester copolymer.