Non-crosslinked Wire Coating Composition Flame Retardancy
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Solution Overview
Problem
Conventional crosslinked resin compositions for insulated wires require large-scale facilities for crosslinking, are costly due to limited coating material options, and compromise on mechanical strength and global supply due to high flame retardant additions, while non-crosslinked resin compositions lack heat and wear resistance.
Innovation Solution
A composition for wire coating members comprising polypropylene, polyolefin elastomer, bromine flame retardant, antimony trioxide, magnesium hydroxide, zinc sulfide or zinc oxide, mercaptobenzimidazole, and hindered phenolic antioxidant, forming a non-crosslinked resin coat with enhanced flame retardancy, heat resistance, and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If crosslinked resin composition is used to achieve flame retardancy, then flame retardancy is improved, but facilities for crosslinking are required which increases device complexity and cost
Solution Approach 1:
The patent extracts the crosslinking step from the manufacturing process by using non-crosslinked resin composition, thereby eliminating the need for complex crosslinking facilities while maintaining flame retardancy through alternative means (proper resin selection and flame retardant formulation)
Solution Approach 2:
The patent adopts a simpler, non-crosslinked resin system that can be processed and applied directly without requiring expensive and complex crosslinking equipment, making the overall system more accessible and cost-effective
2Reliability
If silane functional group is used in coating material to achieve crosslinking, then flame retardancy is improved, but the kind of coating material is limited which increases cost
Solution Approach 1:
The patent removes the constraint of using silane functional groups for crosslinking by adopting a non-crosslinked resin system, thereby expanding coating material selection to include various thermoplastic resins without being limited to silane-based materials
Solution Approach 2:
The patent employs a universal thermoplastic resin base that can accommodate different flame retardant systems and coating formulations, providing greater versatility in material selection compared to the specialized silane-crosslinked system
3Reliability
If great amount of flame retardant is added to achieve flame retardancy, then flame retardancy is improved, but mechanical strength of resin coat decreases
Solution Approach 1:
The patent optimizes the balance between flame retardant content and mechanical properties by carefully controlling the formulation parameters, using a thermoplastic resin base that maintains adequate mechanical strength even with flame retardant addition, unlike crosslinked systems that require high filler loads
4Ease of operation
If non-crosslinked resin composition is used to achieve flexibility and low cost, then flexibility and cost are improved, but heat resistance and wear resistance are insufficient
Solution Approach 1:
The patent creates a composite resin system combining thermoplastic resin with specifically selected flame retardants and additives that collectively provide heat resistance and wear resistance properties, maintaining flexibility without requiring crosslinking
Data Source
AI summary
To provide a composition for a wire coating member containing a non-crosslinked material at a low cost, which has superior flame retardancy, and is excellent in heat resistance, wear resistance and flexibility, and to provide an insulated wire and a wiring harness containing the composition. The composition contains (A) polypropylene, (B) a polyolefin elastomer, (C) a bromine flame retardant, (D) an antimony trioxide, (E) magnesium hydroxide, either one of (F) (F1) a zinc sulfide and (F2) a zinc oxide and (F3) mercaptobenzimidazole, and (G) a hindered phenolic antioxidant. The insulated wire includes a conductor and an insulation coat made from the composition, wherein the insulation coat has a thickness of 0.5 mm or less, and the insulated wire has an external diameter of 4 mm or less. The wiring harness includes the insulated wire.