Insulated Wire Water-Blocking Layer Flame Retardancy

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Solution Overview

Problem

Insulated wires face challenges in achieving a reduced outer diameter while maintaining high levels of flame retardancy, DC stability, and heat resistance, as reducing the thickness of the flame-retardant layer compromises flame retardancy, and reducing the insulation layer thickness affects DC stability.

Innovation Solution

An insulated wire design featuring a flame-retardant insulation layer with a resin composition and a water-blocking layer with low water absorption, where the water-blocking layer prevents water ingress to the flame-retardant layer, allowing it to function for both flame retardancy and DC stability, potentially eliminating the need for a separate insulation layer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of stationary object

If the thickness of the flame-retardant layer is reduced to decrease outer diameter, then weight and size are reduced, but flame retardancy deteriorates

Engineering Contradiction:

Improveouter diameterVSAvoidflame retardancy

Core Design Contradiction:

Weight of stationary objectVSReliability

Solution Approach 1:

The patent uses a composite material approach by combining a flame-retardant resin composition with specific additives (metal hydroxide, nitrogen-containing compound) to create a multi-functional insulation layer that provides both flame retardancy and water blocking properties, eliminating the need for separate layers and reducing overall outer diameter while maintaining performance

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The insulation layer is designed to perform multiple functions simultaneously: electrical insulation, flame retardancy, and water blocking. This multi-functionality is achieved by incorporating specific flame-retardant agents and hydrophobic additives into the resin composition, allowing a single layer to replace what would traditionally require multiple separate layers, thus reducing outer diameter

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Weight of stationary object

If the thickness of the insulation layer is reduced to decrease outer diameter, then weight and size are reduced, but DC stability deteriorates

Engineering Contradiction:

Improveouter diameterVSAvoidDC stability

Core Design Contradiction:

Weight of stationary objectVSReliability

Solution Approach 1:

The patent incorporates hydrophobic additives (wax, fatty acid, silicone oil) into the insulation layer composite material to prevent water absorption and maintain DC stability. This composite approach allows the insulation layer to provide both electrical insulation and water blocking functions, eliminating the need for additional water-blocking layers and reducing outer diameter

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The insulation layer is designed to provide multiple functions including electrical insulation, water blocking, and DC stability maintenance. By integrating hydrophobic properties into the insulation layer material itself, the patent enables a single layer to perform what would traditionally require multiple layers, thus reducing outer diameter while maintaining DC stability

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Weight of stationary object

If the flame-retardant layer is made thinner to reduce outer diameter, then weight is reduced, but heat resistance deteriorates due to oxidation and metal-induced degradation

Engineering Contradiction:

Improveouter diameterVSAvoidheat resistance

Core Design Contradiction:

Weight of stationary objectVSTemperature

Solution Approach 1:

The patent uses a composite resin composition containing flame-retardant agents (metal hydroxide, nitrogen-containing compound) combined with hydrophobic additives and antioxidants. This composite structure provides enhanced heat resistance by preventing oxidation and metal-induced degradation while maintaining flame retardancy, allowing thinner layers that reduce outer diameter without sacrificing heat resistance

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent converts potentially harmful metal ions from the flame-retardant agents into beneficial components by combining them with nitrogen-containing compounds that form protective char structures during combustion. This conversion enhances both flame retardancy and heat resistance, allowing the use of thinner layers that reduce outer diameter while maintaining or improving heat resistance

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 design achieves a reduced outer diameter while maintaining high flame retardancy and DC stability, with the water-blocking layer ensuring the flame-retardant layer's effectiveness and preventing degradation, thus enhancing heat resistance.

Implementation Method 1

a water-blocking layer that is arranged around the flame-retardant insulation layer and has a water absorption of not more than 0.5% at saturation

Methodology Applied

Scientific EffectWater absorption resistance: Absorption (physical)

Data Source

PatentUS11380459B2Insulated wire

Publication Date: 2022.07.05 PROTERIAL LTD

AI summary

An insulated wire includes a conductor, and a flame-retardant insulation layer that includes a resin composition including a flame retardant and is arranged around the conductor, and a water-blocking layer that is arranged around the flame-retardant insulation layer and has a water absorption of not more than 0.5% at saturation. The thickness of the water-blocking layer is not less than 25 μm.