PAS Insulated Wire Coating for Heat Resistance and Flexibility
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Solution Overview
Problem
Insulated wires require high adhesion and ductility to withstand processing stress and high operating temperatures, while poly(arylene sulfide) polymers are often too inflexible or stiff for applications needing flexibility and toughness.
Innovation Solution
An insulated wire with an insulating layer composed of a poly(arylene sulfide) polymer blend, including alkoxysilane, polyorganosiloxane polymer with epoxy functional groups, and optional inorganic filler, providing excellent adhesion and flexibility without the need for intermediate layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If poly(arylene sulfide) polymer is used for the insulating layer, then heat resistance and mechanical strength are improved, but flexibility and toughness deteriorate
Solution Approach 1:
The patent applies composite materials by blending poly(arylene sulfide) polymer with polyorganosiloxane polymer having epoxy functional groups. This combination allows the insulating layer to simultaneously achieve high heat resistance from the PAS polymer and flexibility/toughness from the polyorganosiloxane polymer, resolving the contradiction between thermal stability and mechanical flexibility.
Solution Approach 2:
The patent modifies the chemical composition parameters of the insulating layer by incorporating specific ratios of alkoxysilane (0.1-5 wt%) and polyorganosiloxane polymer with epoxy groups (0.1-10 wt%). These parameter changes transform the material properties to achieve both high heat resistance and improved flexibility/toughness required for wire coating applications.
2Strength
If poly(arylene sulfide) polymer is used for the insulating layer, then mechanical strength is improved, but adhesion to conductor deteriorates
Solution Approach 1:
The patent uses alkoxysilane as an intermediary substance that facilitates adhesion between the poly(arylene sulfide) polymer matrix and the conductor surface. The alkoxysilane contains both organic groups that相容 with the polymer matrix and inorganic silane groups that can bond to the conductor, acting as a molecular bridge to improve interfacial adhesion while maintaining mechanical strength.
Solution Approach 2:
The composite formulation combining poly(arylene sulfide) polymer, polyorganosiloxane polymer with epoxy groups, and alkoxysilane creates a multi-functional material system. The epoxy functional groups on the polyorganosiloxane also contribute to adhesion enhancement, working synergistically with the alkoxysilane to ensure strong bonding to the conductor while maintaining the mechanical strength provided by the PAS polymer.
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 enhances the wire's adhesion to the conductor, improves flexibility, and maintains high heat resistance, making it suitable for high-stress and high-temperature applications.
Implementation Method 1
a polyorganosiloxane polymer having at least one epoxy functional group [polymer (POS)]
Implementation Method 2
composition (C) provides good adhesion to the conductor in the absence of any adhesive or intermediate layer
Implementation Method 3
0.10 to 5.00 wt% of an alkoxysilane [compound (AKS)]
Implementation Method 4
0.10 to 5.00 wt% of an alkoxysilane [compound (AKS)]
Implementation Method 5
stability towards thermal degradation and chemical reactivity
Implementation Method 6
the insulated wire is also required to have a high heat resistance
Data Source
AI summary
The present invention relates to an insulated wire comprising an insulating layer made of a poly(arylene sulfide) composition, possessing improved mechanical performances and outstanding thermal ageing resistance, to a process for its manufacturing, as well as to an article, part or composite material comprising said insulated wire.