Polyolefin Cable Insulation Flame Retardancy

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Solution Overview

Problem

Current cable insulation materials face challenges in achieving excellent flame retardancy, mechanical properties, and cost-effectiveness, with halogenated compounds posing health and environmental hazards, and high-loading inorganic fillers compromising processability and mechanical properties.

Innovation Solution

A composite material is developed using a polyolefin rubber and high-loading mineral fillers like magnesium dihydroxide, cross-linked via electron beam radiation, with additives such as multifunctional acrylates and vinyl silanes to enhance mechanical and electrical properties without the need for expensive nano-fillers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If halogenated compounds are added to enhance flame-retardancy, then flame-retardant properties are improved, but health and environmental hazards increase due to liberation of hazardous gases

Engineering Contradiction:

Improveflame-retardant propertiesVSAvoidhealth and environmental hazards

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent converts the harmful effect of halogenated compounds by replacing them with halogen-free flame retardant fillers (aluminium trihydroxide and magnesium dihydroxide) that decompose endothermically to release water vapor instead of hazardous hydrogen halide gases, thus maintaining flame retardancy while eliminating environmental harm

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent changes the chemical composition parameters by using specific ratios of aluminium trihydroxide (20-40 wt%) and magnesium dihydroxide (40-60 wt%) fillers, combined with silane crosslinking agents, to achieve optimal flame retardant performance without halogenated compounds

Inventive Principle:

Principle #35Parameter changes

2Reliability

If inorganic fillers like aluminium trihydroxide and magnesium dihydroxide are used to achieve flame-retardancy, then flame-retardant properties are improved, but processability and mechanical properties deteriorate due to high filler loading requirements

Engineering Contradiction:

Improveflame-retardant propertiesVSAvoidmechanical properties

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent creates a composite material system combining polyethylene base resin with specific ratios of aluminium trihydroxide and magnesium dihydroxide fillers, along with silane crosslinking agents, to achieve a balanced composite that maintains both flame retardancy and mechanical integrity

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent introduces silane crosslinking agents as intermediaries that form a three-dimensional crosslinked network structure, which binds the inorganic filler particles to the polyethylene matrix, preventing filler aggregation and maintaining mechanical properties despite high filler loading

Inventive Principle:

Principle #24Intermediary (Mediator)

3Stability of the object's composition

If crosslinked polyethylene is prepared by chemical reaction using organic peroxide, then crosslinking is achieved, but health and environmental hazards increase and process complexity increases

Engineering Contradiction:

ImprovecrosslinkingVSAvoidhealth and environmental hazards

Core Design Contradiction:

Stability of the object's compositionVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the chemical crosslinking mechanism using organic peroxides with a silane-based crosslinking system that undergoes condensation reaction to form stable three-dimensional networks, eliminating the need for hazardous peroxide chemicals while achieving equivalent crosslinking density and thermal stability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent uses silane crosslinking agents that can be easily incorporated into the polymer matrix during processing and undergo spontaneous crosslinking upon moisture exposure or heat treatment, providing a simpler, more environmentally friendly alternative to peroxide systems

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 composite material exhibits excellent flame retardancy, mechanical properties, oil resistance, thermal stability, and weathering resistance, while avoiding hazardous gases and maintaining high electrical and mechanical performance, making it suitable for cable applications at a lower cost.

Implementation Method 1

Magnesium dihydroxide decomposes endothermically on burning and liberates inert gases at temperatures higher than 200°C

Methodology Applied

Scientific EffectEndothermic decomposition: Endothermic Reaction

Implementation Method 2

The composite material according to the present invention is prepared by cross-linking a composition by treatment with electron beam radiation

Methodology Applied

Scientific EffectElectron beam crosslinking: Electron Beam

Data Source

PatentEP2522694B1Composite material

Publication Date: 2017.12.06 LAPP ENG

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AI summary

The present invention relates to a composite material consisting of a crosslinked composition. Said composition comprises a 97 to 99 % by weight of a pre-mixture and 1 to 3% by weight of an additive selected from the group consisting of consisting of multifunctional acrylates, multifunctional methacrylates, cyanurates and isocyanurates and substituted vinyl silanes or a mixture thereof. Said pre-mixture comprises 20 to 60 % by weight of a polyolefin rubber and 40 to 80% of mineral fillers. The composite material is used for the preparation of cable insulations.