Power Cable Insulation Resin Composition for Sag-Resistant Extrusion
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Solution Overview
Problem
The use of propylene-based resin in power cable insulating layers results in non-uniform outer diameters due to sagging during cooling, which affects insulation properties and recyclability.
Innovation Solution
A resin composition comprising a propylene-based resin and at least one elastomer or rubber material, with specific viscosity and elastic modulus ranges at different shear rates, is used to stabilize the shape and ensure uniformity of the insulating layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If propylene-based resin is used as insulating layer material, then recyclability and insulation properties are improved, but outer diameter uniformity deteriorates due to sagging during cooling
Solution Approach 1:
The patent applies parameter changes by carefully controlling the viscosity of the propylene-based resin within a specific range (200-5000 Pa·s at high shear rate, 7000-50000 Pa·s at low shear rate) and the elastic modulus (150-700 MPa). These parameter optimizations prevent sagging during cooling while maintaining recyclability and insulation properties, thus resolving the contradiction between reliability and manufacturing precision.
Solution Approach 2:
The patent uses composite materials by formulating a resin composition that includes propylene-based resin combined with other materials (such as elastomers or rubber materials containing specific monomer units). This composite approach enhances the mechanical properties and dimensional stability of the insulating layer, preventing outer diameter non-uniformity while preserving the recyclability and insulation characteristics of the propylene-based resin.
2Ease of manufacture
If propylene-based resin is used as insulating layer material, then recyclability is improved, but shape stability deteriorates due to sagging before cooling
Solution Approach 1:
The patent applies parameter changes by optimizing the viscosity and elastic modulus of the propylene-based resin. The viscosity is controlled within 200-5000 Pa·s at high shear rate (100 s⁻¹) and 7000-50000 Pa·s at low shear rate (1 s⁻¹), while the elastic modulus is maintained at 150-700 MPa. These parameter specifications ensure shape stability during cooling without compromising the recyclability of the propylene-based resin insulating layer.
3Stability of the object's composition
If resin viscosity is increased to prevent sagging, then shape stability is improved, but extrusion processability deteriorates
Solution Approach 1:
The patent applies parameter changes by precisely controlling the viscosity of the propylene-based resin within a balanced range: 200-5000 Pa·s at high shear rate (100 s⁻¹) for good extrusion processability, and 7000-50000 Pa·s at low shear rate (1 s⁻¹) for adequate shape stability. This dual-range viscosity control resolves the contradiction between extrusion processability and shape stability by exploiting the shear-rate dependence of viscosity.
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 resin composition maintains uniform thickness and shape of the insulating layer, enhancing insulation properties and enabling recyclability while preventing sagging.
Implementation Method 1
the resin composition has a viscosity of 200 Pa·s or more and 5000 Pa·s or less at a high shear rate with a shear rate of 100 s−1 at a temperature of 190° C., and a viscosity of 7000 Pa·s or more and 50000 Pa·s or less at a low shear rate with a shear rate of 1 s−1 at a temperature of 190° C.
Data Source
AI summary
A resin composition containing a propylene-based resin and at least one selected from the group of a rubber material and an elastomer, the rubber material and the elastomer each including at least two units from among ethylene, propylene, butylene, hexene, isoprene, octene, and styrene, the resin composition having a viscosity of 200 Pa·s or more and 5000 Pa·s or less at a high shear rate with a shear rate of 100 s−1 at a temperature of 190° C., and a viscosity of 7000 Pa·s or more and 50000 Pa·s or less at a low shear rate with a shear rate of 1 s−1 at a temperature of 190° C., the resin composition having an elastic modulus of 150 MPa or more and 700 MPa or less.