Polypropylene Insulated Wire for Low-Loss High-Heat Data Cables
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Solution Overview
Problem
Existing insulated electric wires for in-vehicle information transmission face challenges in reducing dielectric loss tangent and maintaining heat resistance and bending properties, which affect signal transmission speed and durability.
Innovation Solution
The use of a block polypropylene resin with ethylene units between 0.5 mol% to 25.0 mol%, combined with antioxidants having a hindered phenol structure and copper corrosion inhibitors with triazole, hydrazide, or hydrazine structures, within specific content ranges, to form an insulating layer that reduces dielectric loss tangent and enhances heat resistance and bending properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the dielectric loss tangent of the insulating layer is reduced to increase signal transmission speed, then the transmission speed is improved, but the heat resistance and bending properties may deteriorate
Solution Approach 1:
The patent changes the chemical composition parameters of the insulating layer by specifying precise ranges for antioxidant content (0.01-0.5 mass%) and copper corrosion inhibitor content (0.01-0.5 mass%) relative to the resin component. This parameter optimization allows the material to achieve low dielectric loss tangent while maintaining adequate heat resistance and bending properties through balanced formulation.
Solution Approach 2:
The patent creates a composite insulating layer material combining resin component, antioxidant, and copper corrosion inhibitor in specific proportions. This composite formulation integrates the low dielectric loss characteristics of the resin with the protective and functional properties of the additives, achieving multiple performance requirements simultaneously.
2Reliability
If antioxidants and copper corrosion inhibitors are added to the insulating layer, then heat resistance is improved, but dielectric loss tangent increases
Solution Approach 1:
The patent optimizes the concentration parameters of antioxidants and copper corrosion inhibitors within narrow ranges (0.01-0.5 mass% each). By controlling these parameters precisely, the formulation achieves sufficient heat resistance while minimizing the dielectric loss increase that would result from higher additive concentrations.
Solution Approach 2:
The patent applies the principle of partial action by using minimal effective amounts of antioxidants and copper corrosion inhibitors. Rather than using high concentrations that would guarantee heat resistance, the patent uses low concentrations (0.01-0.5 mass%) that provide adequate protection while causing minimal impact on dielectric loss tangent.
Data Source
AI summary
An insulated wire (1, 11) according to one embodiment of the present disclosure comprises a linear conductor (2) and an insulating layer (3) that is superposed on the outer circumferential surface of the conductor; the insulating layer contains a resin component, an antioxidant and a copper corrosion inhibitors; the resin component is composed of a block polypropylene; the content of ethylene units relative to all monomer units of the resin component is 0.5% by mole to 25.0% by mole; the antioxidant has a hindered phenol structure; the content of the antioxidant is 0.05 part by mass to 0.50 part by mass relative to 100 parts by mass of the resin component; the copper corrosion inhibitors has a triazole structure, a hydrazide structure or a hydrazine structure; and the content of the copper corrosion inhibitors is 0.05 part by mass to 0.50 part by mass relative to 100 parts by mass of the resin component.