TFE/HFP Copolymer Melt Flow Control for Wire Lumping
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Solution Overview
Problem
Conventional techniques fail to adequately prevent the formation of large lumps during the production of electric wires coated with tetrafluoroethylene/hexafluoropropylene (TFE/HFP) copolymers, which hampers productivity and increases defects in molding processes.
Innovation Solution
A TFE/HFP copolymer with a specific melt flow rate, swell percentage, and reduced number of end groups is developed, which minimizes the likelihood of lump formation or reduces the size of lumps if they form, by controlling the melt flow rate between 35.0-45.0 g/10 min, swell between -8.0% to 5.0%, and limiting end groups to ≤120 per 10^6 carbon atoms, thereby enhancing moldability and reducing defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional TFE/HFP copolymers are used for electric wire coating, then insulation properties are maintained, but lump formation occurs during molding reducing productivity
Solution Approach 1:
The patent applies parameter changes by precisely controlling the melt flow rate (35.0-45.0 g/10 min at 372°C) and swell ratio (-8.0% to 5.0%) of the TFE/HFP copolymer. These parameter optimizations enable high-speed extrusion molding while preventing lump formation, directly resolving the contradiction between productivity and manufacturing precision.
2Productivity
If high molding speed is achieved, then productivity increases, but defect formation increases
Solution Approach 1:
The patent optimizes processing parameters by controlling the melt flow rate within 35.0-45.0 g/10 min and swell ratio within -8.0% to 5.0%, enabling high-speed molding at 100 m/min or higher while maintaining low defect rates. This resolves the contradiction between productivity and reliability.
3Ease of manufacture
If copolymer composition is adjusted for better formability, then molding performance improves, but insulation properties may deteriorate
Solution Approach 1:
The patent achieves both good formability and insulation properties by optimizing the HFP content (5-20 mass%) and controlling melt flow rate (35.0-45.0 g/10 min) and swell ratio (-8.0% to 5.0%). This balanced parameter optimization resolves the contradiction between ease of manufacture and reliability.
Data Source
AI summary
Provided is a tetrafluoroethylene/hexafluoropropylene copolymer which is less likely to form a lump, or is less likely to form a large lump even if a lump is formed, during the formation of an electric wire. The tetrafluoroethylene/hexafluoropropylene copolymer has a melt flow rate measured at 372°C of 35.0 to 45.0 g/10 minutes and a swell of -8.0% to 5.0%, the sum of the numbers of -CF2H groups and unstable end groups being 120 or less per 1 × 106 carbon atoms.