Crosslinkable Resin Composition for Continuous Cable Insulation Extrusion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing crosslinkable resin compositions for electric wires/cables cause increased pressure in extruders due to clogging, limiting the continuous formation of insulating coating layers and resulting in shorter production units, which increases the number of connecting joints and failure probability in electric power systems.
Innovation Solution
A crosslinkable resin composition with a hindered amine light stabilizer having a melting point or glass transition point of 100°C or less and molecular weights of 1,500 or less, combined with a hindered phenol stabilizer and dialkyl thiodipropionate, reduces viscosity and prevents clogging, allowing for continuous extrusion molding and longer production units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a screen mesh with smaller mesh size is used to prevent foreign matter mixing, then the quality of insulating coating layer is improved, but clogging and blocking of the screen mesh occurs more quickly, causing pressure increase and stopping extrusion operation
Solution Approach 1:
The patent changes the physical-chemical parameters of the stabilizer by selecting compounds with molecular weights of 1,500 or less and controlling melting points or glass transition points to 100°C or less. This parameter optimization reduces viscosity and prevents solidification/adhesion on screen mesh, allowing continuous operation with fine mesh sizes for high-quality insulation layers.
Solution Approach 2:
The patent introduces dynamic adaptability by ensuring the stabilizer remains in liquid state during extrusion processing through controlled melting points and low molecular weights. This dynamic fluidity allows the stabilizer to flow through fine screen meshes without clogging, maintaining both high filtration quality and continuous operation capability.
2Reliability
If extrusion processing is performed for a long time to increase production unit length, then the number of connecting joints is reduced and failure probability decreases, but pressure in the extruder increases due to screen mesh clogging, causing operation to stop
Solution Approach 1:
The patent optimizes stabilizer parameters (molecular weight ≤1,500, melting point or glass transition point ≤100°C) to maintain low viscosity during extrusion. This prevents clogging of screen mesh, allowing continuous extrusion operation for extended periods to produce longer cable sections with fewer joints and lower failure probability.
Solution Approach 2:
The patent enables continuous extrusion operation by selecting stabilizers that remain fluid throughout the processing period. The low molecular weight and low melting point/glass transition point ensure the stabilizer does not solidify or adhere to screen mesh, maintaining continuous flow and preventing operation interruption.
3Stability of the object's composition
If stabilizer with relatively high viscosity is used, then storage stability is improved, but clogging and blocking of screen mesh occurs, causing pressure increase and preventing stable extrusion processing
Solution Approach 1:
The patent optimizes the molecular weight and melting point/glass transition point parameters of the stabilizer to achieve the right balance: low enough to ensure fluidity during extrusion (molecular weight ≤1,500, melting point ≤100°C) but sufficient to provide adequate storage stability. This parameter optimization allows both stable storage and clog-free extrusion processing.
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 solution prevents pressure increases in extruders, enabling continuous formation of insulating coating layers and increasing the production unit of electric wires/cables, reducing the number of connecting joints and failure probability in electric power systems.
Implementation Method 1
a hindered amine light stabilizer having a melting point or glass transition point of 100°C or less, and specifying molecular weights of all compounds contained in the stabilizer to a certain value or less... Since all compounds contained in the stabilizer (B) have a low molecular weight of 1,500 or less, the viscosities of the compounds are also low.
Implementation Method 2
crosslinking the crosslinkable resin composition to form an insulating coating layer... 0.5 to 3.0 parts by mass of an organic peroxide (C)... and 1.8 wt% dicumyl peroxide
Data Source
AI summary
An object is to provide a crosslinkable resin composition which does not easily cause an increase in the pressure in an extruder charged with the crosslinkable resin composition, and with which an insulating coating layer can be continuously formed by extrusion molding for a long time, thereby realizing an increase in the production unit of an electric wire/cable. A crosslinkable resin composition of the present invention contains 100 parts by mass of an ethylene-based resin (A), a stabilizer (B) containing 0.001 to 0.5 parts by mass of a hindered amine light stabilizer (B3) having a melting point or glass transition point of 100°C or less, and 0.5 to 3.0 parts by mass of an organic peroxide (C). All compounds contained in the stabilizer (B) have a molecular weight of 1,500 or less.