Thermoplastic Polymer Composition for Electric Wire Insulation
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Solution Overview
Problem
Existing thermoplastic polymer compositions for electric wires and cables face challenges in achieving a balance among mechanical strength, elongation at break, flexibility, and heat resistance, with propylene-based polymers offering good heat resistance and mechanical strength but lacking flexibility, and ethylene copolymers providing flexibility but poor scratch resistance and heat resistance.
Innovation Solution
A thermoplastic polymer composition combining an ethylene/unsaturated ester copolymer with specific propylene-based polymers and inorganic fillers, where the propylene-based polymers have defined melting points and molecular weight distributions, and the filler is selected from metal hydroxides, carbonates, or oxides, to enhance dispersibility and balance mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If propylene-based polymers are used to achieve good heat resistance and mechanical strength, then heat resistance and mechanical strength are improved, but flexibility deteriorates
Solution Approach 1:
The patent uses a composite material system comprising propylene-based polymer, ethylene-based copolymer, and inorganic filler. The propylene-based polymer provides mechanical strength and heat resistance, while the ethylene-based copolymer contributes flexibility. The inorganic filler enhances both properties simultaneously, creating a synergistic composite that resolves the contradiction between strength and flexibility.
2Ease of operation
If ethylene copolymers are used to achieve flexibility and impact resistance, then flexibility is improved, but scratch resistance and heat resistance deteriorate
Solution Approach 1:
The patent employs a composite material formulation where ethylene-based copolymer provides the necessary flexibility and impact resistance, while propylene-based polymer and inorganic filler compensate for the deficiencies in scratch resistance and heat resistance. This composite approach allows simultaneous achievement of contradictory properties.
3Strength
If inorganic fillers are added to improve flame retardance and mechanical properties, then heat resistance and mechanical strength are improved, but flexibility and impact resistance deteriorate
Solution Approach 1:
The patent optimizes the content ratio of inorganic filler to polymer components, and carefully selects the types and ratios of propylene-based and ethylene-based polymers. By adjusting these parameters, the negative impact of inorganic fillers on flexibility is compensated while maintaining their beneficial effects on mechanical strength and flame retardance.
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 composition achieves a superior balance of mechanical strength, elongation at break, flexibility, and heat resistance, making it suitable for electric wires and cables with improved scratch resistance and flame retardance.
Implementation Method 1
a propylene-based polymer (B) having a melting point as measured by differential scanning calorimetry (DSC) of from 120 to 170°C; and 1 to 49% by mass of a propylene-based polymer (C) having a melting point as measured by differential scanning calorimetry (DSC) of lower than 120°C or not being observed
Data Source
AI summary
There is provided a thermoplastic polymer composition excellent in the balance among mechanical strength, elongation at break, flexibility and heat resistance, and an article including the composition, and an electric wire and electric cable having an insulator and/or a sheath including the composition. The thermoplastic polymer composition includes 1 to 350 parts by mass of a filler (D) with respect to 100 parts by mass of polymer components that comprise 50 to 90% by mass of an ethylene/unsaturated ester copolymer (A); 1 to 40% by mass of a propylene-based polymer (B) having a melting point as measured by differential scanning calorimetry (DSC) of from 120 to 170°C; and 1 to 49% by mass of a propylene-based polymer (C) having a melting point as measured by differential scanning calorimetry (DSC) of lower than 120°C or not being observed, provided that the total amount of (A), (B) and (C) is 100% by mass.