PPE Resin Wire Covering for Thermal Shrinkage Resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
As electrical facilities increase in capacity and size, the lengths of wiring components also increase, leading to heat generation and thermal shrinkage of the covering resin, causing cracks or displacements.
Innovation Solution
A wiring component with a covering member made of a polyphenylene ether resin composition, designed to have a secondary shrinkage of less than 12.5 × e^(-0.92t%) after thermal aging, achieved by adjusting the composition, increasing the Vicat softening point, and optimizing molding conditions such as mold temperature, resin temperature, and holding pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If the length of wiring component is increased to meet larger electrical facilities, then the capacity and size of electrical facilities can be increased, but heat generation increases causing thermal shrinkage of covering resin, resulting in cracks or displacements
Solution Approach 1:
The patent applies parameter changes by modifying the resin composition parameters - specifically using a resin blend containing polyphenylene ether (PPE) and polyacetal (POM) in specific ratios, adjusting the Vicat softening point to 140°C or higher, and controlling the secondary shrinkage to 3.0% or less. These parameter changes enable the covering member to maintain structural integrity while accommodating longer wiring lengths and associated heat generation.
Solution Approach 2:
The patent employs composite materials by creating a resin composition that blends polyphenylene ether (PPE) and polyacetal (POM) together. This composite material combines the heat resistance of PPE with the mechanical properties of POM, resulting in a covering member that can withstand thermal shrinkage without cracking or displacing, even in long wiring components conducting large amounts of electricity.
2Power
If a large amount of electricity is conducted through long wiring component, then the capacity of electrical facility can be increased, but heat generation causes thermal shrinkage of covering resin leading to damages
Solution Approach 1:
The patent changes the thermal parameters of the covering member by setting the Vicat softening point to 140°C or higher and controlling the secondary shrinkage at 3.0% or less. These parameter changes allow the covering member to resist thermal deformation under high power conditions, preventing cracks and displacements even when large amounts of electricity are conducted through long wiring components.
Solution Approach 2:
The patent uses a composite resin material combining polyphenylene ether and polyacetal to achieve both high heat resistance and low thermal shrinkage. This composite material enables the covering member to withstand the thermal effects of high power transmission without suffering damage, resolving the contradiction between power capacity and thermal shrinkage resistance.
3Ease of manufacture
If conventional resin is used for covering member, then ease of manufacture is maintained, but thermal shrinkage resistance is insufficient causing cracks or displacements under high temperature conditions
Solution Approach 1:
The patent employs a composite resin composition of polyphenylene ether and polyacetal that can be processed using conventional injection molding techniques. This composite material maintains ease of manufacture while providing superior thermal shrinkage resistance (3.0% or less) and crack resistance, eliminating the need for specialized manufacturing processes.
Solution Approach 2:
The patent modifies the resin composition parameters to achieve a Vicat softening point of 140°C or higher and secondary shrinkage of 3.0% or less, while maintaining compatibility with existing manufacturing processes. These parameter changes enable the use of standard injection molding equipment and procedures, preserving ease of manufacture while dramatically improving thermal stability and shrinkage resistance.
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 wiring component is resistant to damages and displacements even when conducting a large amount of electricity, with improved thermal stability and reduced thermal shrinkage.
Implementation Method 1
Heat is generated when a large amount of electricity is conducted through a long wiring component, which may cause thermal shrinkage of a covering resin, resulting in cracks or displacements of the covering resin.
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3B
AI summary
Provided is a wiring component having a covering material which is made to be resistant to damages or displacements even when a large amount of electricity is conducted. A wiring component of the present disclosure is a wiring component including an electrically conductive member having an extension length of 450 mm or more, and a covering member covering the electrically conductive member, wherein the covering member contains a polyphenylene ether resin composition, and has a secondary shrinkage A (%) in an extension length direction of the covering member after being subjected to thermal aging at 130 °C for 24 hours satisfying: A < 12.5 × e-0.92t (in the expression, t represents a thickness (in mm)).