Peroxide Crosslinked Resin Composition for Electric Wire and Cable
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing rubber materials used in electric wires and cables face challenges such as high carbon monoxide emission when burnt, insufficient crosslinking response, and blocking issues during storage and processing, especially when processed into pellet form for extrusion molding.
Innovation Solution
A peroxide crosslinked resin composition comprising a base polymer blend of ethylene α-olefin copolymers with specific density, melt flow rate, and melting point ranges, combined with an inorganic filler and a peroxide crosslinker, which enhances blocking resistance, electrical properties, and reduces toxic gas emission during burning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If rubber material is processed into pellets for extrusion molding, then ease of manufacture is improved, but blocking prominently manifests and molding becomes difficult
Solution Approach 1:
The invention changes the physical and chemical parameters of the rubber material by adding specific inorganic fillers (such as calcium carbonate, talc, or silica) and lubricants to the base polymer. These additives modify the material's flow characteristics, melting behavior, and inter-pellet adhesion properties, enabling pellet form without prominent blocking while maintaining extrusion molding capability
Solution Approach 2:
The invention creates a composite material system consisting of base polymer (ethylene-α-olefin copolymer), inorganic fillers, lubricants, and crosslinking agents. This composite formulation combines the benefits of pellet processability with blocking resistance, as the inorganic fillers and lubricants work synergistically to prevent pellet adhesion while maintaining material integrity during storage and processing
2Reliability
If non-polar polymer is used to maintain electrical properties in water, then electrical insulation is improved, but carbon monoxide emission increases when burnt
Solution Approach 1:
The invention modifies the compositional parameters of the non-polar polymer by incorporating specific inorganic fillers and additives that alter the combustion characteristics. The inorganic fillers (calcium carbonate, talc, silica) serve as carbon monoxide suppressants during combustion while maintaining the non-polar nature of the base polymer for electrical insulation in water
Solution Approach 2:
The invention converts the harmful effect of carbon monoxide emission during combustion into a benefit by using inorganic fillers that act as combustion modifiers. These fillers reduce toxic gas emission while the non-polar polymer matrix maintains electrical insulation properties, thus transforming a harmful characteristic into a controlled and beneficial outcome
3Ease of manufacture
If ethylene α-olefin copolymer with melting point not higher than 100 degrees Celsius is used, then ease of extrusion molding is improved, but scorching occurs during extrusion molding with organic peroxide
Solution Approach 1:
The invention changes the thermal and rheological parameters of the polymer by selecting specific ethylene-α-olefin copolymers with controlled melting points and molecular weights, and by adding inorganic fillers and lubricants. These parameter modifications allow extrusion molding at temperatures that prevent peroxide decomposition while maintaining material flowability
Solution Approach 2:
The invention introduces inorganic fillers and lubricants as intermediary substances that mediate between the polymer matrix and the extrusion process. These intermediaries facilitate smooth extrusion at lower temperatures, preventing direct thermal contact between the organic peroxide and high-temperature zones that would cause scorching
4Strength
If rubber material is used for crosslinking, then mechanical strength is improved, but blocking occurs during storage at ordinary temperature
Solution Approach 1:
The invention changes the physical parameters of the rubber material by incorporating inorganic fillers and lubricants that reduce inter-pellet adhesion forces. These additives modify the surface properties and flow characteristics, preventing blocking during storage while maintaining the crosslinking capability for mechanical strength development
Solution Approach 2:
The invention uses lubricants and inorganic fillers as temporary, disposable additives that prevent blocking during storage and processing but do not interfere with the permanent crosslinked structure. These short-term functional additives are consumed or remain inert after serving their protective function, leaving the crosslinked network intact for long-term mechanical strength
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 composition achieves excellent blocking resistance in pellet form during storage, maintains electrical properties when submerged in water, and suppresses toxic gas emission when burnt, while allowing for flexible molding conditions and improved mechanical strength.
Implementation Method 1
a peroxide crosslinked resin composition includes: a base polymer (A) including 50 to 90% by mass of a first copolymer component (a1) comprising one of or a mixture of two or more first ethylene α-olefin copolymers... and a peroxide crosslinker (C)
Data Source
AI summary
A peroxide crosslinked resin composition includes a base polymer (A) including 50 to 90% by mass of a first copolymer component (a1) including one of or a mixture of two or more first ethylene α-olefin copolymers having a density of 0.864 to 0.890 g/cm3, a melt flow rate (MFR) of 1 to 5 g/10 min, and a melting point of not higher than 90 degrees Celsius, and 10 to 50% by mass of a second copolymer component (a2) including one of or a mixture of two or more second ethylene α-olefin copolymers having a melt flow rate (MFR) of not smaller than 30 g/10 min, and a melting point of 55 to 80 degrees Celsius, an inorganic filler (B) added in a ratio of from 80 parts to 150 parts by mass with respect to 100 parts by mass of the base polymer (A), and a peroxide crosslinker (C).