Crosslinked Resin Cable Sheathing for Heat Resistance
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Solution Overview
Problem
Existing cable sheathing materials lack sufficient flexibility and heat resistance, particularly in narrow and short paths, where silicone rubber cables are costly and require specialized manufacturing, and other materials do not meet high enough flexibility standards.
Innovation Solution
A resin composition combining an ethylene-(meth)acrylate ester copolymer with ethylene-propylene-diene terpolymer or ethylene-acrylate rubber, crosslinked with radiation, and incorporating a flame retardant, optimized to provide both flexibility and heat resistance as a sheathing layer for cables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If silicone rubber is used as the sheathing material, then flexibility and heat resistance are improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent changes the chemical composition parameters of the resin by incorporating specific additives (ethylene-propylene-diene terpolymer, ethylene-acrylate rubber, and flame retardant) to achieve heat resistance comparable to silicone rubber while maintaining compatibility with conventional extrusion molding processes
Solution Approach 2:
The patent replaces expensive silicone rubber with a cost-effective resin composition that can be processed using conventional equipment, eliminating the need for specialized vulcanization devices and hot air treatment apparatus
2Temperature
If silicone rubber is used as the sheathing material, then flexibility and heat resistance are improved, but device complexity increases
Solution Approach 1:
The resin composition is designed to be universally compatible with conventional extrusion molding equipment, performing multiple functions including heat resistance, flexibility, and processability that were previously requiring specialized silicone rubber processing equipment
3Ease of manufacture
If conventional insulating materials are used, then cost is reduced, but flexibility and heat resistance are insufficient
Solution Approach 1:
The patent creates a composite resin system combining base resin with ethylene-propylene-diene terpolymer, ethylene-acrylate rubber, and flame retardant additives to achieve enhanced heat resistance and flexibility while maintaining cost-effectiveness
4Ease of manufacture
If conventional insulating materials are used, then cost is reduced, but flexibility is insufficient
Solution Approach 1:
The patent modifies the physical and chemical parameters of the resin composition by incorporating elastomeric components and plasticizers to achieve flexibility levels sufficient for narrow and short path applications while maintaining cost advantages over silicone rubber
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 achieves improved flexibility and heat resistance, allowing for effective use in automotive applications, with a tensile stress of 2.0 MPa or less at 19% strain and heat resistance up to 150°C, while reducing costs and manufacturing complexity.
Implementation Method 1
the resin component is crosslinked
Data Source
Figure 1
AI summary
The resin composition contains: a resin component containing an ethylene-(meth)acrylate ester copolymer and at least one of an ethylene-propylene-diene terpolymer or ethylene-acrylate rubber; and a flame retardant, and the resin component is crosslinked. The tensile stress at 19% strain of the resin composition is 2.0 MPa or less, and the resin composition has heat resistance at 150°C prescribed in JASO D624.