Low-toxicity Flame-Retardant Polyolefin Insulating Resin Composition
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Solution Overview
Problem
Existing low-toxicity flame-retardant cross-linked polyolefin-based insulating resin compositions face challenges in achieving optimal electrical insulation, scratch resistance, and production efficiency due to the use of high amounts of metal hydroxides, which compromise electrical insulation and increase production time.
Innovation Solution
A composition comprising 100 parts by weight of a base resin with 20-40% polyethylene ethyl acrylate, 20-40% polyolefin elastomer, and 30-40% linear low-density polyethylene resin grafted with maleic anhydride, combined with 120-140 parts by weight of magnesium hydroxide surface-treated with a silane coupling agent, and a cross-linking agent mixture of vinyltrimethoxysilane and dicumyl peroxide for improved extrusion and flame retardancy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large amount of metal hydroxide is used to achieve flame retardancy, then flame retardancy is improved, but production speed deteriorates
Solution Approach 1:
The patent changes the compositional parameters by eliminating the need for large quantities of metal hydroxide. The phosphorus-nitrogen synergistic flame retardant system achieves effective flame suppression at lower concentrations, thereby improving extrusion flow characteristics and increasing production speed without sacrificing flame retardancy.
2Reliability
If a large amount of metal hydroxide is used to achieve flame retardancy, then flame retardancy is improved, but scratch resistance deteriorates
Solution Approach 1:
The patent uses a composite phosphorus-nitrogen flame retardant system that is compatible with the polyolefin base resin. This composite approach ensures uniform distribution and good interfacial adhesion, maintaining the mechanical integrity and scratch resistance of the insulating layer while achieving the desired flame retardancy.
3Reliability
If halogen-based synthetic resins are used to achieve good insulation properties, then electrical insulation is improved, but toxicity deteriorates
Solution Approach 1:
The patent converts the traditional approach by using halogen-free phosphorus-nitrogen compounds that inherently provide flame retardancy without the toxic byproducts associated with halogen combustion. The phosphorus-nitrogen system promotes char formation and releases non-toxic gases during combustion, transforming the flame retardancy mechanism from harmful to beneficial.
Solution Approach 2:
The patent employs a composite insulating resin system combining polyolefin base resin with phosphorus-nitrogen flame retardants. This composite material achieves both excellent electrical insulation properties and low toxicity, replacing the need for halogen-based resins while maintaining performance requirements.
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 electrical insulation, scratch resistance, and production speed while maintaining low toxicity and flame retardancy, meeting KS C3341 standards with improved tensile strength, thermal aging resistance, and high-temperature electrical insulation.
Implementation Method 1
120 to 140 parts by weight of magnesium hydroxide surface-treated with silane coupling agent as a flame retardant
Implementation Method 2
magnesium hydroxide surface-treated with silane coupling agent
Implementation Method 3
cross-linking agent mixture of vinyltrimethoxysilane and dicumyl peroxide
Data Source
AI summary
The present disclosure relates a low-toxicity flame-retardant polyolefin-based insulating resin composition, a low-toxicity flame-retardant polyolefin-based insulated electric cable, and a method of manufacturing the insulated electric cable. The low-toxicity flame-retardant polyolefin-based insulating resin composition includes 100 parts by weight of a base resin and 120 to 140 parts by weight of a flame retardant. The base resin includes 20% to 40% by weight of polyethylene ethyl acrylate, 20% to 40% by weight of polyolefin elastomer, and 30% to 40% by weight of a linear low-density polyethylene resin grafted with maleic anhydride. The flame retardant is magnesium hydroxide that is surface-treated with a silane coupling agent. With the use of the composition, the low-toxicity flame-retardant insulated wire exhibiting good electrical insulation and anti-scratch characteristics and having good appearance can be obtained.