Heat-Resistant Electric Wire Using Modified Fluoropolymer Coating
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Solution Overview
Problem
Existing heat-resistant electric wires face challenges with insufficient heat resistance and crack resistance, and those with tetrafluoroethylene/perfluoro(alkyl vinyl ether) copolymers have issues with extrusion molding and deformation at high temperatures.
Innovation Solution
A heat-resistant electric wire is developed using a modified fluorine-containing copolymer coating formed by irradiating a copolymer with radiation at 250 kGy or lower, comprising tetrafluoroethylene and perfluoro(alkyl vinyl ether) units, which provides excellent heat resistance and crack resistance, allowing for easy extrusion molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If tetrafluoroethylene/perfluoro(alkyl vinyl ether) copolymer is used for coating, then extrusion molding is possible, but heat resistance and crack resistance are insufficient
Solution Approach 1:
The patent applies parameter changes by controlling the composition ratios of tetrafluoroethylene (5-40 mass%) and perfluoro(alkyl vinyl ether) (60-95 mass%) in the copolymer, and by controlling the molecular weight (weight average molecular weight: 10,000-1,000,000). These parameter adjustments optimize both the extrusion processability and the resulting heat/crack resistance of the coating.
Solution Approach 2:
The patent uses a composite material approach by creating a copolymer that combines tetrafluoroethylene units and perfluoro(alkyl vinyl ether) units in specific ratios. This composite polymer structure integrates the extrusion processability of tetrafluoroethylene with the enhanced heat resistance of perfluoro(alkyl vinyl ether), resolving the contradiction between manufacturability and reliability.
2Reliability
If polyimide coating is used, then heat resistance is improved, but incombustibility is insufficient and extrusion molding is impossible
Solution Approach 1:
The patent changes the material parameter from polyimide to a specific fluorinated copolymer with controlled composition (5-40 mass% TFE, 60-95 mass% PAVE) and molecular weight (10,000-1,000,000). This parameter change enables extrusion molding while maintaining heat resistance, and the fluorinated structure provides inherent incombustibility that polyimide lacks.
Solution Approach 2:
The patent replaces the complex polyimide synthesis process with a copolymer that can be processed by simple extrusion molding. The copolymer coating can be applied as a thin layer (1-100 μm) that provides the required performance, eliminating the need for thick polyimide coatings and complex sintering processes.
3Reliability
If polytetrafluoroethylene coating is used, then heat resistance is excellent, but extrusion molding is impossible
Solution Approach 1:
The patent modifies the polytetrafluoroethylene structure by incorporating perfluoro(alkyl vinyl ether) units (60-95 mass%) to create a copolymer with lower molecular weight (10,000-1,000,000) and specific composition ratios. These parameter changes reduce the melting point and improve processability for extrusion molding while retaining the excellent heat resistance of the fluorinated structure.
Solution Approach 2:
The patent creates a composite polymer system by combining tetrafluoroethylene and perfluoro(alkyl vinyl ether) units in a copolymer structure. This composite material maintains the heat resistance of polytetrafluoroethylene while the incorporated PAVE units provide chain flexibility and lower crystallinity, enabling extrusion molding processability.
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 an electric wire that maintains shape and resistance at temperatures above its melting point, preventing deformation and improving performance in high-temperature environments.
Implementation Method 1
a modified fluorine-containing copolymer that is obtained by irradiating a copolymer with radiation at an exposure of 250 kGy or lower at a temperature of not higher than the melting point of the copolymer
Data Source
AI summary
The present invention aims to provide an electric wire that is capable of being produced by extrusion molding and is excellent in heat resistance and crack resistance. The present invention relates to a heat-resistant electric wire including a core wire and a coating that covers the core wire. The coating is formed from a modified fluorine-containing copolymer that is obtained by irradiating a copolymer with radiation at an exposure of 250 kGy or lower at a temperature of not higher than the melting point of the copolymer. The copolymer is at least one copolymer selected from the group consisting of a copolymer including a tetrafluoroethylene unit and a perfluoro(alkyl vinyl ether) unit and a copolymer including a tetrafluoroethylene unit and a hexafluoropropylene unit.