Non-Halogen Multilayer Insulated Wire Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing non-halogen multilayer insulated wires fail to meet the stringent requirements of European EN standards for abrasion resistance, hydrolysis resistance, flame retardance, heat resistance, electrical properties, and low smoke emission while maintaining low toxicity.
Innovation Solution
A non-halogen multilayer insulated wire design featuring a conductor covered by an inner polyolefin resin composition and an outer polyester resin composition, including high density polyethylene, ethylene copolymer, metal damage inhibitor, polyester block copolymer, hydrolysis inhibitor, inorganic porous filler, and magnesium hydroxide, which enhances abrasion resistance, hydrolysis resistance, flame retardance, and electrical properties while minimizing smoke emission and toxicity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If halogen-free materials are used to reduce environmental impact and improve fire safety, then flame retardance and low smoke emission are improved, but abrasion resistance and hydrolysis resistance deteriorate
Solution Approach 1:
The patent uses a composite material system consisting of polyester resin as the base polymer combined with polyester block copolymer (50-150 parts by mass per 100 parts base polymer), hydrolysis inhibitor, inorganic porous filler, and magnesium hydroxide (10-30 parts by mass per 100 parts base polymer). This composite structure achieves both flame retardance and mechanical strength requirements of EN standards.
Solution Approach 2:
The patent optimizes the content ratios of specific components within defined ranges: polyester block copolymer at 50-150 parts by mass per 100 parts base polymer, and magnesium hydroxide at 10-30 parts by mass per 100 parts base polymer. These parameter adjustments balance flame retardance, abrasion resistance, and hydrolysis resistance to meet EN standards.
2Reliability
If halogen-free materials are used to reduce environmental impact and improve fire safety, then flame retardance and low smoke emission are improved, but hydrolysis resistance deteriorates
Solution Approach 1:
The patent introduces a hydrolysis inhibitor as an intermediary substance that specifically protects the polyester resin from hydrolysis degradation. This inhibitor acts as a mediator between the polyester resin and moisture, preventing harmful chemical reactions while maintaining the material's flame retardant properties.
Solution Approach 2:
The composite material system combines polyester resin with hydrolysis inhibitor, polyester block copolymer, inorganic porous filler, and magnesium hydroxide. This multi-component composite achieves both flame retardance and hydrolysis resistance simultaneously, overcoming the limitations of single-material solutions.
3Object-generated harmful factors
If non-halogen material is used to achieve low smoke emission and low toxicity, then environmental compliance is improved, but electrical properties (direct current stability) deteriorate
Solution Approach 1:
The patent carefully controls the content of magnesium hydroxide within 10-30 parts by mass per 100 parts base polymer and inorganic porous filler within 0.5-5 parts by mass per 100 parts base polymer. These optimized parameters ensure sufficient flame retardance and low smoke emission while maintaining electrical insulation properties and direct current stability required by EN standards.
Solution Approach 2:
The patent uses inorganic porous filler with specific surface area of 5 m²/g or more to provide localized fire protection and smoke suppression without compromising the bulk electrical insulation properties. The filler creates a protective barrier that affects only the fire-related properties while leaving electrical properties intact.
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 proposed wire configuration effectively meets EN standards by providing superior abrasion resistance, hydrolysis resistance, flame retardance, heat resistance, and electrical stability while ensuring low smoke emission and low toxicity, thus enhancing safety and environmental compliance.
Implementation Method 1
the outer layer includes a polyester resin composition that includes a base polymer mainly including a polyester resin, and further includes, relative to 100 parts by mass of the base polymer, 50 to 150 parts by mass of a polyester block copolymer, 0.5 to 5 parts by mass of a hydrolysis inhibitor, 0.5 to 5 parts by mass of an inorganic porous filler, and 10 to 30 parts by mass of magnesium hydroxide
Implementation Method 2
0.5 to 5 parts by mass of a hydrolysis inhibitor
Data Source
AI summary
A non-halogen multilayer insulated wire includes a conductor, an inner layer covering the conductor, and an outer layer formed on the external surface of the inner layer. The inner layer includes a polyolefin resin composition including 60 to 95 parts by mass of a high density polyethylene, 5 to 40 parts by mass of an ethylene copolymer, and 0.1 to 1 part by mass of a metal damage inhibitor. The outer layer includes a polyester resin composition that includes a base polymer mainly including a polyester resin, and further includes, relative to 100 parts by mass of the base polymer, 50 to 150 parts by mass of a polyester block copolymer, 0.5 to 5 parts by mass of a hydrolysis inhibitor, 0.5 to 5 parts by mass of an inorganic porous filler, and 10 to 30 parts by mass of magnesium hydroxide.