Poly(arylene ether) Composition for Flexible Covered Conductors

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Solution Overview

Problem

There is a need for a thermoplastic composition with excellent mechanical properties and processability to address the limitations of polyethylene compositions, which often result in deterioration of mechanical properties and processability due to high inorganic flame retardant levels, and to meet the increasing demand for flexible and durable cables and wires in compact electronic devices and automotive applications.

Innovation Solution

A thermoplastic composition comprising a poly(arylene ether) with an intrinsic viscosity greater than 0.25 dl/g, combined with a styrenic resin, a polyolefin resin, and optionally a flame retardant and compatibilizer, which provides improved mechanical properties and flexibility while meeting performance requirements such as ISO 6722 standards.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If polyethylene compositions with high levels of inorganic flame retardant are used, then flame retardancy is improved, but mechanical properties and processability deteriorate

Engineering Contradiction:

Improveflame retardancyVSAvoidmechanical properties

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent uses a composite material system consisting of polyethylene base resin combined with specific organic flame retardants (such as phosphorus-containing compounds) and processing aids. This composite approach replaces the reliance on high levels of inorganic flame retardants, achieving flame retardancy through the synergistic effect of organic additives while maintaining the mechanical integrity and processability of the polyethylene matrix.

Inventive Principle:

Principle #40Composite materials

2Ease of operation

If the insulation layer thickness is reduced to achieve flexibility, then flexibility is improved, but thermal life and durability deteriorate due to copper catalyzed degradation

Engineering Contradiction:

ImproveflexibilityVSAvoidthermal life

Core Design Contradiction:

Ease of operationVSDuration of action of stationary object

Solution Approach 1:

The patent introduces stabilizers and metal deactivators as intermediary substances between the copper conductor and the polyethylene insulation. These additives act as protective mediators that prevent copper ions from catalyzing degradation of the insulation material, even when the insulation thickness is reduced. The stabilizers absorb or neutralize the harmful copper ions, allowing thin-walled flexible cables to maintain long thermal life and durability.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent modifies the chemical composition parameters of the polyethylene insulation by incorporating specific additives (stabilizers, antioxidants, and metal deactivators) in optimized concentrations. This parameter change transforms the insulation material's resistance to copper-catalyzed degradation, enabling thin-walled cables to achieve both flexibility and extended thermal life at elevated temperatures.

Inventive Principle:

Principle #35Parameter changes

3Temperature

If crosslinked polyethylene is used for insulation, then thermal resistance is improved, but flexibility and processability deteriorate

Engineering Contradiction:

Improvethermal resistanceVSAvoidflexibility

Core Design Contradiction:

TemperatureVSEase of operation

Solution Approach 1:

The patent applies partial crosslinking or uses polyethylene compositions with controlled crosslinking density rather than full crosslinking. This partial action approach maintains sufficient flexibility and processability while providing enhanced thermal resistance. The composition achieves optimal balance by incorporating crosslinking agents in controlled amounts or using physical crosslinking mechanisms that preserve material flexibility.

Inventive Principle:

Principle #16Partial or excessive action

Data Source

PatentUS8871866B2Poly(arylene ether) composition and a covered conductor with flexible covering wall and large size conductor

Publication Date: 2014.10.28 SHPP GLOBAL TECH BV

AI summary

Disclosed herein is covered conductors with a normal to large conductor cross-section area (AWG 5 to AWG 24). The thickness of the coating can be, for example, 0.25 to 8.0 millimeter (mm). Also disclosed are a thermoplastic composition comprising a poly(arylene ether) having an intrinsic viscosity greater than 0.25 dl/g as measured in chloroform at 25° C., a styrenic resin, a polyolefin resin, and optionally a flame retardant, a compatibilizer, or a combination of a flame retardant and a compatibilizer. The coating comprises the thermoplastic composition described above.