Multilayer Electrical Wire Insulation Adhesion
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Solution Overview
Problem
Conventional electrical wire insulation materials with a two-layer structure suffer from weak interlayer adhesive force, leading to poor resistance against wrinkling, bending fatigue, and mechanical properties, as well as poor withstanding voltage characteristics after heating, and excessive adhesion issues.
Innovation Solution
A composition for manufacturing insulation materials with a multilayer structure, using a first insulation coating layer made of a blended resin including polyethylene and an antioxidant, and a second layer made of polyvinylidene fluoride with a co-crosslinking agent, to enhance adhesive force and mechanical properties while maintaining thermal resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the outer layer is exposed to mechanical stress or contacted with sharp-edged substances, then the outer layer may be peeled from the inner layer due to insufficient adhesive force, but improving adhesion strength may cause excessive adhesion that deteriorates withstanding voltage characteristic after heating
Solution Approach 1:
The patent modifies the chemical composition parameters of the resin blend in the inner layer, specifically incorporating polyethylene grafted with maleic anhydride at controlled ratios (5-50 parts by weight per 100 parts polyethylene) along with specific antioxidants and crosslinking agents. These parameter changes optimize the adhesive properties while maintaining thermal stability and electrical characteristics after heating.
Solution Approach 2:
The invention uses a composite resin composition in the inner layer combining polyethylene, polyethylene grafted with maleic anhydride, antioxidants, and crosslinking agents. This composite material structure provides balanced properties: sufficient adhesion to the PVDF outer layer, resistance to peeling under mechanical stress, and maintained withstanding voltage characteristics after thermal exposure.
2Strength
If the outer layer is exposed to mechanical stress from outside environment, then cracks may be generated in the outer layer, but using conventional single-layer or two-layer structures without proper composition control does not improve mechanical resistance
Solution Approach 1:
The patent optimizes the compositional parameters including the ratio of polyethylene to polyethylene grafted with maleic anhydride (5-50:100 parts by weight), antioxidant content (0.1-5 parts by weight per 100 parts resin), and crosslinking agent content (0.1-5 parts by weight per 100 parts resin). These parameter adjustments enhance crack resistance and mechanical strength without requiring complex multi-layer structures.
Solution Approach 2:
The polyethylene grafted with maleic anhydride acts as an intermediary component between the polyethylene matrix and the PVDF outer layer. The grafted maleic anhydride groups provide polar interactions that improve interfacial adhesion and stress transfer, preventing crack initiation and propagation while maintaining compositional simplicity.
3Strength
If conventional insulation materials are used, then manufacturing is simple, but resistance against wrinkling upon bending is weak and resistance against wear or bending fatigue is deteriorated
Solution Approach 1:
The invention adjusts key compositional parameters: incorporating 5-50 parts by weight of polyethylene grafted with maleic anhydride per 100 parts polyethylene, adding 0.1-5 parts by weight of antioxidants, and 0.1-5 parts by weight of crosslinking agents. These parameter modifications enhance flexibility, wear resistance, and bending fatigue resistance while maintaining compatibility with conventional extrusion manufacturing processes.
Solution Approach 2:
The patent enhances specific local properties of the inner layer by incorporating functional additives at optimized concentrations. The polyethylene grafted with maleic anhydride provides localized adhesion enhancement at the interface with the outer layer, while antioxidants and crosslinking agents provide localized resistance to environmental degradation and mechanical fatigue, without affecting the overall manufacturing simplicity.
4Strength
If conventional insulation materials are used, then the structure is simple, but mechanical properties are deteriorated and thermal resistance is poor, unable to maintain physical properties at high temperature of at least 150°C for a long time
Solution Approach 1:
The patent optimizes compositional parameters for high-temperature performance: incorporating polyethylene grafted with maleic anhydride (5-50 parts per 100 parts polyethylene), antioxidants (0.1-5 parts per 100 parts resin), and crosslinking agents (0.1-5 parts per 100 parts resin). These parameter changes enable the insulation material to maintain mechanical integrity and thermal resistance at temperatures of at least 150°C for extended periods.
Solution Approach 2:
The invention creates a composite resin system in the inner layer combining polyethylene, polyethylene grafted with maleic anhydride, antioxidants, and crosslinking agents. This composite structure provides synergistic effects: the grafted polyethylene enhances interfacial adhesion and thermal stability, antioxidants prevent thermal degradation, and crosslinking agents form a three-dimensional network that maintains mechanical properties at elevated temperatures.
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 solution provides improved mechanical and thermal resistance, ensuring the insulation materials maintain physical properties at high temperatures (at least 150°C) and prevents peeling, while maintaining a balance between adhesive strength and ease of peeling.
Implementation Method 1
an antioxidant and a co-crosslinking agent so as to surround a conductor or a conductor bundle for an electrical wire
Implementation Method 2
a co-crosslinking agent so as to surround a conductor or a conductor bundle for an electrical wire; a second insulation coating layer manufactured with a composition including a base resin polyvinylidene fluoride (PVDF), a predetermined antioxidant and a co-crosslinking agent
Data Source
AI summary
A composition for manufacturing insulation materials of an electrical wire having a multilayer structure, which is used for manufacturing a first insulation coating layer made of a composition including a predetermined base resin, an antioxidant and a co-crosslinking agent so as to surround a conductor or a conductor bundle for an electrical wire; a second insulation coating layer made of a composition including a base resin polyvinylidene fluoride (PVDF), a predetermined antioxidant and a co-crosslinking agent so as to surround the first insulation coating layer, and an electrical wire manufactured using the same.