UV-Crosslinked Polyolefin Wire Insulation Bleed-Out Control
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Solution Overview
Problem
Existing methods struggle to inhibit bleed-out from ultraviolet cross-linked insulating layers containing polyolefin while maintaining a small relative dielectric constant, which is essential for preventing signal transmission loss and deformation in small-diameter electrical wires and cables.
Innovation Solution
The use of a resin composition comprising a base polymer with polyolefin and a compatibilizer, along with a photoradical generator and a reactive monomer, where the photoradical generator is between 0.5 to 3 parts by mass and the reactive monomer is between 1 to 5 parts by mass relative to 100 parts of the base polymer, and the addition of specific compatibilizers like hydrogenated styrene butadiene rubber to promote uniform cross-linking and inhibit bleed-out.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If a nucleating agent and/or thickening agent is added to inhibit bleed-out, then bleed-out is inhibited, but the relative dielectric constant increases
Solution Approach 1:
The invention changes the concentration parameters of reactive monomer (1-5 parts by mass) and photoradical generator (0.5-3 parts by mass) to achieve effective cross-linking without requiring additional nucleating agents or thickening agents, thus preventing bleed-out while maintaining low relative dielectric constant
Solution Approach 2:
The invention creates a composite resin composition combining polyolefin base polymer with specific amounts of reactive monomer and photoradical generator, achieving both bleed-out inhibition and low dielectric constant through the synergistic effect of these components
2Temperature
If cross-linking is performed to increase heat distortion resistance, then heat distortion resistance is improved, but bleed-out occurs from the insulating layer
Solution Approach 1:
The invention optimizes the concentration parameters of reactive monomer (1-5 parts by mass) and photoradical generator (0.5-3 parts by mass) to achieve effective cross-linking without excessive bleed-out, balancing heat distortion resistance with material stability
Solution Approach 2:
The photoradical generator acts as an intermediary that enables cross-linking reaction to proceed at lower temperatures and shorter times, reducing thermal stress and bleed-out while achieving the desired heat distortion resistance
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
This approach effectively inhibits bleed-out and maintains a low relative dielectric constant of less than 2.5 in the insulating layer, enhancing mechanical properties and ensuring stable signal transmission without deformation.
Implementation Method 1
cross-linking the insulating layer by irradiating the insulating layer with an ultraviolet ray
Data Source
AI summary
An electrical wire includes a conductor and an insulating layer that covers the conductor and that is cross-linked. The insulating layer is a cross-linked product of a resin composition including (a) a base polymer containing polyolefin and a compatibilizer, (b) a photoradical generator of 0.5 parts by mass or more and 3 parts by mass or less relative to the 100 parts by mass of the base polymer, and (c) a reactive monomer of 1 part by mass or more and 5 parts by mass or less relative to the 100 parts by mass of the base polymer. A relative dielectric constant of the insulating layer is less than 2.5.