PVC Wire Coating with Polyester Elastomer for Heat Resistance
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Solution Overview
Problem
Conventional insulated electric wires with polyvinyl chloride insulators face issues with flexibility, heat resistance, and manufacturing costs due to high viscosity and equipment expenses, especially when trying to increase flexibility and heat deformability resistance.
Innovation Solution
A composition combining polyvinyl chloride with 40-80 parts by mass plasticizer and 10-80 parts by mass polyester elastomer, which has a melting point of at least 190°C and a tensile modulus of not more than 300 MPa, eliminating the need for expensive electron beam crosslinking and minimizing inorganic filler usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the amount of plasticizer is increased to improve flexibility, then flexibility is improved, but heat resistance (fusibility resistance and heat deformability resistance) deteriorates
Solution Approach 1:
The patent uses a composite material system consisting of polyvinyl chloride resin, plasticizer, and polyester elastomer. The polyester elastomer component (10-80 parts by mass per 100 parts by mass of polyvinyl chloride) provides thermal stability and reinforces the plasticizer-polyvinyl chloride matrix, allowing high plasticizer content (40-80 parts by mass) to be used while maintaining both flexibility and heat resistance through synergistic material combination
Solution Approach 2:
The patent changes the chemical composition parameters of the insulator material by introducing polyester elastomer with specific properties (melting point ≥190°C, tensile modulus ≤300 MPa). This parameter change in material composition allows the system to achieve both high flexibility (through plasticizer) and high heat resistance (through polyester elastomer's thermal stability) simultaneously
2Reliability
If electron beam crosslinking is used to improve fusibility resistance and heat deformability resistance, then heat resistance is improved, but manufacturing cost increases due to expensive equipment
Solution Approach 1:
The patent replaces expensive electron beam crosslinking equipment with a conventional extrusion process using a composition that inherently provides heat resistance through polyester elastomer addition. This substitutes capital-intensive equipment (electron beam apparatus) with standard manufacturing equipment, dramatically reducing manufacturing cost while achieving comparable or superior heat resistance through material composition rather than post-processing
Solution Approach 2:
The patent changes the approach from process modification (electron beam crosslinking) to composition modification (adding polyester elastomer to the resin composition). By changing the material parameters (composing with polyester elastomer having melting point ≥190°C), the patent achieves heat resistance without requiring expensive crosslinking equipment, thereby reducing manufacturing cost
3Reliability
If polyvinyl chloride with high degree of polymerization or inorganic filler is used to improve heat resistance, then fusibility resistance is improved, but manufacturability decreases due to increased viscosity and appearance defects
Solution Approach 1:
The patent uses polyester elastomer as a composite additive (10-80 parts by mass per 100 parts by mass of polyvinyl chloride) that provides heat resistance through its high melting point (≥190°C) without significantly increasing the viscosity of the resin composition. This composite approach maintains good manufacturability and appearance quality while achieving fusibility resistance, avoiding the viscosity and defect problems associated with high polymerization degree polyvinyl chloride or inorganic fillers
Solution Approach 2:
The patent changes the heat resistance mechanism from relying on high polymerization degree or inorganic filler content to relying on polyester elastomer composition. The polyester elastomer parameters (melting point ≥190°C, tensile modulus ≤300 MPa) are specifically selected to provide thermal stability while maintaining low viscosity and good processability, thereby improving fusibility resistance without sacrificing manufacturability or appearance quality
Data Source
AI summary
A composition for an electric wire coating material containing polyvinyl chloride includes a plasticizer in an amount of 40 to 80 parts by mass with respect to 100 parts by mass of the polyvinyl chloride, and a polyester elastomer.