Crosslinked Wire Insulation With Reversible Ionic Bonds
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Solution Overview
Problem
Crosslinked polymer compositions used in insulated wires and wiring harnesses face challenges in achieving both high heat resistance and re-formability, as crosslinking processes like electron-beam crosslinking and silane crosslinking result in irreversible bonds, making it difficult to re-form the material into different shapes.
Innovation Solution
A crosslinkable polymer composition that includes a metal ion-releasing ingredient A and an organic polymer with electron-withdrawing substituent groups in its side chain, allowing for ionic bonding and reversible crosslinking, which maintains high heat resistance while enabling re-formability by adjusting the flow starting temperature between 190°C and 300°C.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If crosslinking is performed using electron-beam crosslinking or silane crosslinking to improve heat resistance, then heat resistance is improved, but re-formability deteriorates due to irreversible covalent bonds
Solution Approach 1:
The patent changes the bonding mechanism from irreversible covalent bonds to reversible ionic bonds between metal ions and carboxylic acid groups. This parameter change in bond type allows the material to maintain heat resistance through crosslinking while enabling re-formability by heating, as the ionic bonds can be reversibly broken and reformed
Solution Approach 2:
The patent introduces metal ions as intermediary components that mediate the crosslinking between polymer chains. These metal ions form ionic bonds with carboxylic acid groups on adjacent polymer chains, creating a reversible crosslinking system that provides both heat resistance and re-formability, unlike direct covalent bonding
2Temperature
If a polymer material with high flow starting temperature is used to achieve high heat resistance, then heat resistance is improved, but forming difficulty increases due to high temperature heating requirements
Solution Approach 1:
The patent performs crosslinking after the forming process rather than before. The polymer composition is first formed into the desired shape at lower temperatures, then crosslinked by heating to form ionic bonds between metal ions and carboxylic acid groups. This preliminary forming followed by crosslinking resolves the contradiction between forming ease and heat 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
The crosslinked polymer material exhibits both high heat resistance and re-formability, allowing for shape changes without irreversible deformation, suitable for applications in automotive wires and wiring harnesses.
Implementation Method 1
ingredient B includes, in the side chain, an electron-withdrawing substituent group capable of forming an ionic bond with the metal ion released from ingredient A
Implementation Method 2
the crosslinked product has a flow starting temperature of 190° C. or higher and 300° C. or lower
Data Source
AI summary
A a crosslinkable polymer composition which provides a crosslinked product capable of both heat resistance and re-formability, a crosslinked polymer material capable of both heat resistance and re-formability, and an insulated wire and a wiring harness including the crosslinked polymer material. The crosslinkable polymer composition includes: ingredient A from which metal ion is released by heat; and ingredient B including an organic polymer having a side chain, including an electron-withdrawing substituent group capable of forming an ionic bond with the metal ion, and when B is crosslinked via the metal ion to form a crosslinked product, the product has a flow starting temperature of 190° C. or higher and 300° C. or lower. The crosslinked polymer material includes the crosslinked product of the crosslinkable polymer composition. The insulated wire includes a wire conductor, and an insulation coating including the crosslinked polymer material, and the wiring harness including the insulated wire.