Ethylene-Polymer Wire Insulation for Extrusion and Strength
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional electric wires using polyethylene insulating materials lack excellence in extrusion processability, electric resistance property, and mechanical strength, necessitating improvements for better performance and appearance.
Innovation Solution
An electric wire coated with an insulating material containing ethylene as a main component, meeting specific density, melt flow rate, volume resistivity, shear viscosity, and environmental stress cracking resistance criteria, optionally crosslinked with agents to enhance mechanical and electrical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional polyethylene is used as insulating material, then electric insulation property is good, but extrusion processability and mechanical strength are insufficient
Solution Approach 1:
The patent applies parameter changes by precisely controlling the density of ethylene polymer within 900-925 kg/m³ and melt flow rate within 5-20 g/10min. These parameter optimizations enable the material to achieve both good extrusion processability and maintained electric insulation properties, resolving the contradiction between manufacturability and reliability.
2Reliability
If conventional polyethylene is used as insulating material, then electric insulation property is good, but mechanical strength is insufficient
Solution Approach 1:
The patent employs composite materials by combining ethylene polymer with specific additives including crosslinking agents (peroxides, silanes), flame retardants (metal hydroxides), and antioxidants. This composite approach enhances mechanical strength and adds functional properties while maintaining the excellent electric insulation characteristics of the base polyethylene material.
3Strength
If crosslinking agent is compounded and crosslinked, then surface smoothness and mechanical strength are improved, but process complexity increases
Solution Approach 1:
The patent applies preliminary action by incorporating crosslinking agents (such as peroxides or silanes) directly into the insulating material formulation during manufacturing. The actual crosslinking reaction then occurs in situ during or after the extrusion process, eliminating the need for separate crosslinking equipment or multi-step processing, thus reducing overall process complexity while achieving enhanced mechanical strength.
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 electric wire achieves improved extrusion processability, enhanced electric resistance, mechanical strength, and a satisfactory appearance, with the option for flame retardancy through inorganic additives, forming a durable and eco-friendly coating layer.
Implementation Method 1
an insulating material containing a polymer containing ethylene as a main component... excellent in an electric resistance property
Implementation Method 2
When the above-described insulating material is crosslinked by various methods, the surface of the coating layer formed of the insulating material becomes smooth, and the coating layer can be more excellent in, for example, mechanical strength
Data Source
AI summary
An electric wire having a coating layer that is excellent in an electric resistance property and mechanical strength and that has a satisfactory appearance is provided by using an insulating material that is excellent in extrusion processability containing a polymer containing ethylene as a main component. The electric wire includes a conductor or a conductor-shielding layer that is coated with the insulating material containing a polymer containing ethylene as a main component, wherein, with regard to the polymer containing ethylene as a main component, a density is in a specific range; a melt flow rate (MFR) is in a specific range; a volume resistivity (Ω·cm) is in a specific range; a shear viscosity (Pa·s) is in a range that forms a specific flow curve; and a 50% failure time (F50) in an environmental stress cracking resistance test (E.S.C.R. test) is in a specific range.