Multicore Cable Core Wire Insulation for Low-Temperature Flex Durability
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Solution Overview
Problem
In-vehicle multicore cables require core electric wires with high abrasion resistance and bending durability, especially at low temperatures, due to exposure and complex routing within vehicles.
Innovation Solution
A core electric wire for multicore cables is developed, comprising a conductor of twisted elemental wires with an insulating layer made of a polyethylene-based resin blend, including high-density polyethylene, a copolymer of ethylene and α-olefin with a carbonyl group, and very-low density polyethylene, with specific content ratios and optionally linear low-density or low-density polyethylene, enhancing abrasion resistance and low-temperature bending durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional insulating layer material is used, then the manufacturing process is simple, but the abrasion resistance and bending durability at low temperatures are insufficient
Solution Approach 1:
The insulating layer uses a composite resin composition containing multiple polyethylene components (HDPE, LLDPE, VLDPE) with specific density ranges and content ratios. This composite structure combines the abrasion resistance of HDPE with the flexibility and low-temperature performance of LLDPE and VLDPE, achieving both high reliability and controlled complexity through defined material specifications.
Solution Approach 2:
The patent specifies precise parameter ranges for each resin component: HDPE density (0.935-0.970 g/cm³) at 30-70 mass%, LLDPE density (0.910-0.935 g/cm³) at 10-50 mass%, and VLDPE density (0.905-0.915 g/cm³) at 10-40 mass%. By controlling these physical parameters and content ratios, the invention optimizes the balance between abrasion resistance and low-temperature bending durability while maintaining manufacturability.
Data Source
AI summary
A core electric wire for a multicore cable. The core electric wire includes a conductor composed of a plurality of elemental wires twisted together and an insulating layer coating a circumference of the conductor. The insulating layer includes a first component and a second component, the first component being high density polyethylene, the second component being at least one selected from the group consisting of a copolymer of ethylene and an α-olefin having a carbonyl group, and very-low density polyethylene. The first component has a content ratio of 10% by mass or more and 60% by mass or less to a total content of the polyethylene-based resin, and the second component has a content ratio of 20% by mass or more and 80% by mass or less to the total content of the polyethylene-based resin.