Silane Crosslinkable Polyolefin Wire Process
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Solution Overview
Problem
Existing processes for producing electrical wire molded bodies with silane crosslinkable flame retardant polyolefins struggle to achieve both high flame retardance and physical properties like heat resistance, strength, and flexibility due to issues with uniform dispersibility of metal hydrates and complex crosslinking steps, leading to inadequate performance under strict safety and performance standards.
Innovation Solution
A process involving the production of a silane crosslinkable flame retardant polyolefin component with specific ratios of polyethylene-based resin, organic peroxide, silane coupling agent, and metal hydrate, combined with a silanol catalyst resin composition, and then melt molding and crosslinking in the presence of water to achieve uniform crosslinking and improved properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a polyolefin-based resin is used as base polymer with large amount of metal hydrate flame retardant, then flame retardance is improved, but flexibility and molding processability deteriorate
Solution Approach 1:
The patent changes the chemical structure parameter of the base polymer from crystalline polyolefin to low-crystalline polyolefin, fundamentally altering the material properties to reduce rigidity while maintaining flame retardance through crosslinking
Solution Approach 2:
The patent creates a composite system combining low-crystalline polyolefin base polymer with metal hydrate flame retardant and crosslinking agents, achieving synergistic effects where the composite provides both flame retardance and flexibility that individual components cannot achieve alone
2Strength
If crystalline polyolefin is used as base polymer, then strength is improved, but flexibility and molding processability deteriorate
Solution Approach 1:
The patent changes the crystallinity parameter of the polyolefin from high to low, transforming the material from rigid to flexible while compensating for strength loss through crosslinking chemistry
Solution Approach 2:
The patent introduces crosslinking agents as intermediary substances that mediate between the low-crystalline polyolefin chains, creating a network structure that provides strength without requiring high crystallinity
3Ease of operation
If low-crystalline polyolefin is used to reduce rigidity, then flexibility is improved, but strength and heat resistance deteriorate
Solution Approach 1:
The patent introduces crosslinking agents as intermediary substances that mediate between the low-crystalline polyolefin chains, creating a network structure that provides strength without requiring high crystallinity
4Manufacturing precision
If silane crosslinking is performed with large amount of metal hydrate, then crosslinking degree is improved, but early crosslinking occurs causing uniformity deterioration
Solution Approach 1:
The patent segments the crosslinking process into two distinct stages: first forming the silane-modified polyolefin component, then performing crosslinking in the molding step, preventing early crosslinking during mixing while ensuring sufficient crosslinking in the final product
Solution Approach 2:
The patent performs preliminary silane modification of the polyolefin before mixing with metal hydrate, preparing the crosslinking capability in advance while delaying actual crosslinking until the molding stage when uniformity can be maintained
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 process efficiently produces electrical wire molded bodies with enhanced flame retardance, heat resistance, strength, elongation, and appearance, making them suitable for severe environments like solar cables, while ensuring high safety and performance standards.
Implementation Method 1
melting and kneading 30 parts to 100 parts by weight of component (a) polyethylene-based resin, 0 part to 40 parts by weight of component (b) polypropylene-based resin, 0 part to 40 parts by weight of component (c) block copolymer of an aromatic vinyl-based compound and a conjugated diene-based compound and/or a hydrogenated product thereof, 0 part to 15 parts by weight of component (d) acid-modified resin and 0 part to 30 parts by weight of component (e) non-aromatic softening agent for rubber (provided that the total amount of the components (a), (b), (c), (d) and (e) is defined as 100 parts by weight), and 0.2 part to 1 part by weight of component (f) organic peroxide, 1 part to 6 parts by weight of component (g) silane coupling agent
Implementation Method 2
silane crosslinking for an electrical wire molded body made of a polyolefin composition comprising a large amount of a metal hydrate as a flame retardant involves the problem of attaining a sufficient degree of crosslinking
Implementation Method 3
producing a silanol catalyst resin composition comprising a polymer and a silanol condensation catalyst in a specific weight ratio, and then melting and mixing the silane crosslinkable flame retardant polyolefin component and the silanol catalyst composition in a specific weight ratio and molding the mixture, and then crosslinking the molded body in the presence of water
Implementation Method 4
those comprising a polyolefin-based resin as a base polymer and a metal hydrate such as aluminum hydroxide or magnesium hydroxide in a large amount as a flame retardant
Implementation Method 5
melting and kneading 30 parts to 100 parts by weight of component (a) polyethylene-based resin, 0 part to 40 parts by weight of component (b) polypropylene-based resin
Implementation Method 6
melting and mixing the silane crosslinkable flame retardant polyolefin component and the silanol catalyst composition in a specific weight ratio
Data Source
AI summary
There are provided a process for producing an electrical wire molded body comprising: step I of melting and kneading a polyethylene-based resin (a), a polypropylene-based resin (b), a block copolymer (c) of an aromatic vinyl-based compound and a conjugated diene-based compound and the like, and a silane coupling agent (g), and other components, to produce a silane crosslinkable flame retardant polyolefin (A); step II of melting and kneading a polymer selected from the components (a) to (c) and a silanol condensation catalyst (i), to produce a silanol catalyst rein composition (B); and step III of mixing the components (A) and (B), melt molding the mixture on a conductor and then crosslinking the molded body in the presence of water.