KR20070087114A - Electrical wire and method of making an electrical wire - Google Patents

Abstract

An electrical wire and a method of making an electrical wire are disclosed. The electrical wire comprises a conductor and a covering. The covering comprises a thermoplastic composition comprising a poly(arylene ether), a polyolefin and a polymeric compatibilizer. The thermoplastic composition may further comprise a flame retardant.

Description

Wire and wire manufacturing method {ELECTRICAL WIRE AND METHOD OF MAKING AN ELECTRICAL WIRE}

This application is directed to US Provisional Application Nos. 60 / 637,406, 60 / 637,008, 60 / 637,412, and 60 / 637,419 and 2005, filed Dec. 17, 2004, which is hereby incorporated by reference in its entirety. Priority application of US Provisional Application No. 60 / 654,247, filed May 18.

Wires have been used in a wide range of applications. In many applications the conductor is surrounded by an electrically insulating thermoplastic coating. Many requirements for insulated thermoplastic coatings vary depending on the manner and method in which the wire is used, but many applications, particularly high voltage applications, such as automotive underhood applications, require no spark leakage in the insulated thermoplastic coating. Spark leaks are caused by defects such as pinholes in the insulating coating surrounding the wire. In the production of electric wires for automotive applications, the wires are tested for spark leaks, and if a spark leak is found, the wire is cut and the compartment containing the spark leak is discarded. The presence of spark leaks during manufacture disrupts line continuity and reduces productivity. Since the lines must be cut to remove the compartments containing the spark leak, lines with different lengths are created. These lengths typically combine to form the overall overall length that is packaged and sold.

Wires are typically sold in containers or on spools containing the total amount of wire length, which is determined in part by the cross-sectional area of the conductor. Remove wires from spools or containers for use in various products such as automotive wiring harnesses. For example, for a wire having a conductor having a cross-sectional area of 0.14 mm ² to 1.00 mm ² , the total length of the lines on the spool may be 13,500 to 15,500 m, and the number of individual lines on the spool may be 1 to 6, where each The minimum length of the line is 150m. Spools or containers containing a greater number of individual wires or shorter wires often result in lower productivity and higher yields in the manufacture of products from wires.

Automotive wires, located under the hood of the engine compartment, have been insulated with a single high temperature insulating layer disposed on copper conductors that are not conventionally coated. Thermoplastic polyesters, crosslinked polyethylenes and halogenated resins such as fluoropolymers, polyvinyl chlorides not only provide heat resistance but also the need for the high temperature insulation required in this challenging environment requiring compound resistance, flame retardancy and flexibility. It has been satisfied for a long time.

The thermoplastic polyester insulating layer has excellent resistance to gases and oils, is mechanically robust and resistant to copper catalyzed decomposition, but can rupture prematurely due to hydrolysis. In addition, the insulating layer of the thermoplastic polyester insulated wire was also found to crack when exposed to hot, salty water, and burst when subjected to a humid temperature cycle.

Due to their negative impact on the environment, there is an increasing demand to reduce or eliminate the use of halogenated resins in insulating layers. In fact, many countries are beginning to prescribe reductions in the use of halogenated materials. However, since most of the line coating extrusion apparatus are made based on the specifications of halogenated resins such as polyvinyl chloride, any alternative material must be able to be handled in a similar manner to polyvinyl chloride.

Crosslinked polyethylene has been largely successful in providing high temperature insulation, but this success can be difficult to maintain as far as requirements for automotive wires are concerned. As more electronics are used in today's cars, the amount of wiring in the car is growing exponentially. A significant increase in wiring motivates automakers to define reduced insulation layer thickness and to reduce the overall wire diameter by defining smaller conductor sizes. For example, ISO 6722 specifies that for conductors with a cross-sectional area of 2.5 μm ² , the thin wall insulation thickness is 0.35 mm and the ultra thin wall insulation thickness is 0.25 mm.

Reducing the insulation wall thickness adds difficulty when using crosslinked polyethylene. In the case of crosslinked polyethylene, a thinner insulating layer thickness results in a shorter heating life when aged at oven temperatures between 150 ° C and 180 ° C. This limits their temperature rating. For example, a wire having a copper conductor with an adjacent crosslinked polyethylene insulation layer with a 0.75 mm wall thickness is flexible, and the insulation layer does not crack when wound on a mandrel after exposure at 150 ° C. for 3000 hours. However, using a similar wire having a crosslinked polyethylene insulation layer having a wall thickness of 0.25 mm, the insulation layer becomes brittle after being exposed at 150 ° C. for 3000 hours. The detrimental effect created by this very thin wall requirement is due to copper catalyzed decomposition, which is widely recognized as a problem in the industry.

Thus, there is a need for wires that are suitable for use in automotive environments and that are free of halogenated resins and methods of making such wires.

Brief Description of the Invention

The necessity disclosed above is a conductor; And a coating disposed on a conductor, the thermoplastic composition comprising (i) a poly (arylene ether), (ii) a polyolefin, and (iii) a polymerization compatibilizer, wherein the conductor is 0.15 mm ² to 1.00 mm ^For wires having a cross-sectional area of ² , the covering having a thickness of 0.15 to 0.25 mm, and for a total length of 13,500 to 15,500 m, there are no more than six individual lengths of wire, and each individual length of line Satisfied by a wire having a length of 150m or more. The thermoplastic composition may further comprise a flame retardant.

In another aspect, the wire comprises a conductor; And a coating disposed on a conductor, the thermoplastic composition comprising (i) a poly (arylene ether), (ii) a polyolefin, and (iii) a polymerization compatibilizer, wherein the coating material also comprises 2,500 to 15,500 m In the case of lines, there are less than five spark leaks.

In another aspect, a method of making a wire comprises melt mixing poly (arylene ether), polyolefin, and a polymerization compatibilizer to form a first mixture; Melt filtering the first mixture through a first filter having an opening having a diameter of 20 to 150 μm to form a first filtered mixture; Melt filtering the first filtered mixture through a second filter having an opening having a diameter of 20 to 150 μm to form a second filtered mixture; And applying the second filtered mixture to the conductor.

In another aspect, a method of making a wire comprises melt filtration of a composition comprising poly (arylene ether), polyolefin, and a polymerization compatibilizer to form a filtered composition; Applying the filtered composition to a conductor to form a wire having less than three spark leaks per wire of 2500 to 15,500 meters.

In another embodiment, the coating includes a thermoplastic composition comprising (i) a poly (arylene ether), (ii) a polyolefin, and (iii) a polymeric compatibilizer, wherein the wire comprising the coating disposed on the conductor comprises: For lines 2,500 to 15,500m, there are no more than five spark leaks. The thermoplastic composition may further comprise a flame retardant.

In another embodiment, the coating includes a thermoplastic composition comprising (i) poly (arylene ether), (ii) polyolefin, and (iii) polymerization compatibilizer, wherein the thermoplastic composition is substantially free of particulate impurities. The thermoplastic composition may further comprise a flame retardant.

In another embodiment, the coating can comprise melt mixing poly (arylene ether), polyolefin and a polymerization compatibilizer to form a mixture; And a thermoplastic composition produced by the method comprising melt filtering the mixture through a filter.

1 is a schematic diagram of a cross section of an electric wire.

2 and 3 are perspective views of wires having multiple layers.

In the following specification and claims, reference is made to a number of terms that are defined as having the following meanings.

Singular forms include the plural unless the context clearly dictates otherwise.

“Optionally” means that an event or situation that is subsequently disclosed does or does not occur, and this description includes cases where an event does and does not occur.

All ranges of end points that refer to the same property are independently combinable and include the end points mentioned. Values expressed as "over" or "less than" include the end point mentioned, for example "greater than 3.5" includes a value of 3.5.

ISO 6722, referred to herein, is a version dated December 15, 2002 of this standard.

Poly (arylene ether) / polyolefin blends are unlikely to be chosen as the polymeric coating of wires for a number of reasons. Compositions of these types have often been used in applications requiring stiffness, but were generally considered unsuitable for applications requiring flexibility, such as wires. In addition, poly (arylene ether) / polyolefin blends as disclosed herein have poly (arylene ether) dispersed in a polyolefin matrix. Since the known problem of copper catalyzed decomposition in polyolefins is known, it does not appear that a composition having a polyolefin matrix can be used successfully in an environment where copper catalyzed decomposition is possible. Poly (arylene ether) also has a tendency to form particulates and gels when exposed to temperatures above its glass transition temperature (Tg), increasing the likelihood of defects producing spark leakage in the polymer coating.

Methods of preparing cladding materials for use in wires with low or no spark leakage typically include melt blending (compounding) components for thermoplastic compositions used to form polymeric coatings in melt mixing devices, such as compounding extruders or Banbury mixers. Pounding). In one embodiment, the poly (arylene ether), polymerization compatibilizer and polyolefin are melt mixed simultaneously. In another embodiment, the poly (arylene ether), polymerization compatibilizer and optionally some of the polyolefins are melt mixed to form a first melt mixture. Subsequently, the polyolefin or the remainder of the polyolefin is further melt mixed with the first melt mixture to form a second melt mixture. Alternatively, some of the poly (arylene ether) and a portion of the polymerization compatibilizer are melt mixed to form a first melt mixture, and then the remaining portion of the polyolefin and the polymerization compatibilizer is further melt mixed with the first melt mixture to form a second melt. Forms a mixture.

The above-described melt mixing process may be performed without isolating the first melt mixture or may be performed by isolating the first melt mixture. One or more melt mixing devices may be used in this process, including one or more types of melt mixing devices. In one embodiment, some components of the thermoplastic composition forming the coating can be introduced and melt mixed into an extruder used for conductor coating.

Poly (arylene ether) and 50 when the polymeric compatibilizer comprises two block copolymers, one having an aryl alkylene content of at least 50% by weight and the second having an aryl alkylene content of less than 50% by weight. The first copolymer may be melt mixed with a block copolymer having an aryl alkylene content of at least% by weight to form a first melt mixture and the melt copolymer with a polyolefin and a block copolymer having an aryl alkylene content of at most 50% by weight may be melt mixed with the first melt mixture. To form a second melt mixture.

Selective flame retardant addition methods and locations are typically dictated by the type and physical properties of the flame retardant (eg, solid or liquid), as well as those understood in the general field of polymer alloys and their preparation. In one embodiment, the flame retardant is combined with one of the components of the thermoplastic composition, for example a portion of the polyolefin, to form a concentrate that will subsequently be melt mixed with the remaining components.

Poly (arylene ether), polymerization compatibilizers, polyolefins and optionally flame retardants are melt mixed above the glass transition temperature of poly (arylene ether) but below the decomposition temperature of polyolefins. For example, poly (arylene ether), polymerization compatibilizers, polyolefins and optionally flame retardants may be melt mixed at an extruder temperature of 240 ° C. to 320 ° C., in which an excess of a short period of time may occur during melt mixing. Within this range, the temperature may be at least 250 ° C, more particularly at least 260 ° C. Within this range, the temperature may be 310 ° C. or lower, more particularly 300 ° C. or lower.

After melt mixing some or all of the components, the molten mixture may be melt filtered through one or more filters having openings having a diameter of 20 μm to 150 μm. Within this range, the opening can have a diameter of 130 μm or less, more particularly 110 μm or less. Also within this range, the openings may have a diameter of at least 30 μm, more in particular at least 40 μm.

Any suitable melt filtration system or apparatus capable of removing particulate impurities from the molten mixture may be used. In one embodiment the melt is filtered through a single melt filtration system. Multiple melt filtration systems are also envisaged.

Suitable melt filtration systems include filters made of various materials, such as, but not limited to, calcined metal, metal mesh or screen, fiber metal felt, ceramic, or combinations of the foregoing materials, and the like. Particularly useful filters are calcined metal filters that exhibit high torsional properties, including calcined line mesh filters manufactured by Pall Corporation and Martin Kurz & Company, Inc.

Any type of melt filter can be used, including, but not limited to, conical, pleated, candle shaped, laminated, flat, wrapped, screens, cartridges, pack discs, and combinations of the foregoing. The choice of form can vary depending on various variables such as the size of the extruder, the desired throughput rate, and the degree of particle filtration desired. Exemplary construction materials include stainless steel, titanium, nickel and other metal alloys. Various weaves of sun fabric can be used, including combinations of plain, dutch, square, twill, and weave. Particularly useful are filters designed to minimize internal volume, have a small flow area, and withstand repeated cleaning cycles.

The melt filtration system may include a periodic or continuous screen exchange filter or batch filter. For example, a continuous screen exchange filter may comprise a ribbon of screen filter that is slowly passed into the melt flow passage of the extruder. The melt mixture passes through a filter, the filter collects particulate impurities inside the melt, which impurities are moved out of the extruder using a filter ribbon, and the extruder is periodically or continuously updated with the ribbon of the new compartment.

In one embodiment, the filter opening has a maximum diameter of less than half the thickness of the coating to be applied to the conductor. For example, if the wire has a 200 μm thick covering, the filter opening has a maximum diameter of 100 μm or less.

The minimum size of the filter openings depends on a number of variables. Smaller filter openings can create greater pressure on the upstream side of the filter. Therefore, the filter opening and operating method must be chosen to prevent unsafe pressure on the upstream side. In addition, a filter with a filter opening of less than 20 μm may produce poor flow both upstream and downstream of the filter. Poor flow can extend the residence time of some portions of the melt mixture. Longer residence times can cause the production or expansion of particulates in the composition, which when applied to a conductor can cause spark leakage.

In one embodiment, the melt filtered mixture is passed through a die head and pelletized by either strand pelletization or sub-pelletization. The pelletized material can be packaged, stored and transported. In one embodiment, the pellets are packaged in metal foil lined plastic bags, typically polypropylene bags or metal foil lined paper bags. Substantially all air can be removed from the pellet filled bags.

In one embodiment, the thermoplastic composition is substantially free of particulate impurities. Visible particulates or “black stains” are dark or colored particulates that are generally visible to the human eye without magnification and have an average diameter of 40 μm or greater. Although some may visually detect particles having an average diameter of less than 30 μm without enlarging, others may only detect particles having an average diameter of greater than 40 μm, but the term “visible particles” herein. When "visible fine particles" and "black spots" are used without mentioning a defined average diameter, it means fine particles having an average diameter of 40 mu m or more. As used herein, when applied to a thermoplastic composition, the term “substantially free of particulate impurities” refers to injection molding the composition to form five plaques having dimensions of 75 mm × 50 mm and thickness of 3 mm and using black with naked eyes. Visual examination of the plaques in all respects to the stains means that the total number of black stains for all five plaques is 100 or less, more particularly 70 or less, even more particularly 50 or less.

In one embodiment, the pellets are melted and the composition is applied to the conductor by a suitable method such as extrusion coating to form an electric wire. For example, a coating extruder equipped with a screw, crosshead, breaker plate, distributor, nipple and die can be used. The molten thermoplastic composition forms a coating disposed on the circumference of the conductor. Extrusion coating can use a single taper die, double taper die, other suitable die, or a combination of dies to center the conductor and avoid accumulation of die lips.

In one embodiment, the composition is applied to a conductor to form a coating disposed on the conductor. Additional layers can be applied on the coating.

In one aspect, the composition is applied to a conductor having at least one intervening layer between the conductor and the coating to form a coating disposed on the conductor. For example, an optional adhesion improving layer can be disposed between the conductor and the coating. In another example, the metal deactivator may be coated on the conductor before applying the coating. In another example, the intervening layer includes a thermoplastic or thermoset composition that in some cases is foamed.

The conductor may comprise a single strand or a plurality of strands. In some cases, multiple strands may be bundled, twisted, or braided to form conductors. In addition, the conductor may have various forms of round or oval. The conductor may be any type of conductor used to carry a signal. Exemplary signals include optical, electrical and electromagnetic. Glass fiber is an example of an optical conductor. Suitable electrical conductors include, but are not limited to, alloys comprising copper, aluminum, lead and one or more of the aforementioned metals. The conductor may also be an electrically conductive ink or paste.

The cross-sectional area of the conductor and the thickness of the sheath may vary and are typically determined by the end use of the wire. In one aspect, the wire includes, but is not limited to, for example, work lines for automobiles, lines for household appliances, power lines, facility lines, lines for information transmission, lines for electric vehicles, ships, airplanes, and the like. Can be used as a wire. In one aspect, the coated conductor is an optical cable and can be used for internal use (in the building), external use (outside the building), or both internal and external use. Exemplary uses include data delivery networks and voice delivery networks, such as telephone networks and on-premises information networks (LANs).

In some embodiments, it may be useful to dry the thermoplastic composition prior to extrusion coating. Exemplary drying conditions are 2 to 20 hours at 60 to 90 ° C. Also, in one embodiment, during extrusion coating, the thermoplastic composition is melt filtered through one or more filters having an opening diameter of 20 μm to 150 μm prior to forming the coating. Within this range, the opening diameter can be at least 30 μm, more in particular at least 40 μm. Within this range, the opening diameter may be 130 μm or less, more particularly 110 μm or less. The coated extruder may comprise one or more filters as disclosed above.

In one embodiment, during extrusion coating, the thermoplastic composition is melt filtered through one or more filters having an opening diameter prior to forming the coating, wherein the filter opening has a maximum diameter of less than half the thickness of the coating to be applied to the conductor. For example, if the wire has a 200 μm thick covering, the filter opening has a maximum diameter of 100 μm or less.

In another embodiment, the melt filtered mixture produced by melt mixing is not pelletized. Rather, a coating extruder, typically a compounding extruder, associated with the melt mixing device is used to form the melt filtered mixture directly into the coating for the conductor. The coated extruder may comprise one or more filters as disclosed above.

Color concentrates or masterbatches may be added to the composition prior to or during extrusion coating. When color concentrates are used, they are typically present in amounts up to 3% by weight, based on the total weight of the composition. In one embodiment, the dyes and / or pigments used in the color concentrates are free of chlorine, bromine and fluorine. As will be appreciated by those skilled in the art, the color of the composition prior to adding the color concentrate affects the final color obtained, and in some cases it may be advantageous to use bleach and / or color stabilizer. Bleaches and color stabilizers are known in the art and are commercially available.

The extruder temperature during extrusion coating is 320 ° C. or lower, more particularly 310 ° C. or lower, more particularly 290 ° C. or lower. In addition, the processing temperature is adjusted to provide a molten composition that is sufficiently fluid to provide a coating for the conductor, for example higher than the melting point of the thermoplastic composition, more particularly at least 10 ° C. above the melting point of the thermoplastic composition.

After extrusion coating, the wires are generally cooled using a water bath, water spray, air jet, or a combination comprising one or more of the cooling methods described above. Exemplary water bath temperatures are 20 to 85 ° C. The water may be deionized or filtered to remove impurities. As mentioned above, an in-line method is used to check for spark leaks in the wires. Exemplary methods for testing spark leakage include using a conductor of the wire as a grounded electrode and passing the wire through or through the charged electrode such that the wire is in contact with the charged electrode. If the polymer coating on the wire contains defects such as pinholes or cracks, an arc is generated and detected between the charged electrode and the conductor of the wire. Exemplary charged electrodes include bead chains and brushes. The electrodes can be charged using alternating current or direct current as indicated by the end use of the wire and any relevant industry regulations for the wire. The voltage can be measured by one skilled in the art of spark leak testing. The frequency used depends on the load capacity and can also be measured by one skilled in the art of spark leakage testing. Spark test equipment is commercially available, for example, from The Clinton Instrument Company, Beta LaserMike and Zumbach.

If a spark leak is detected, the wire is cut to remove the spark leak. Thus, each spark leak creates a new length of line. After checking for spark leakage, the wire can be wound on a spool or similar device. Exemplary winding speeds are from 50 m / min to 1500 m / min. The wire may be placed in a container with or without a spool or similar device. Lines of different lengths can be combined to make lines up to the full length of a vessel or spool or similar device. The overall length of the wires placed in a vessel or spool or similar device generally depends on the cross sectional area of the conductor and the thickness of the cladding.

The length of the wire between the spark leaks is important. If the container of the wire contains a section of wire having a length of less than 150 m, the wire may be inefficient to use because the wire is used in a continuous manner to construct various products, such as wire harnesses and the like. . The work flow must be broken to start the wire in the new compartment. In addition, the use of electrical wires is also inefficient if there are six or more individual electrical wire compartments per container. Thus, both the amount and frequency of spark leaks are important.

Therefore, when the wire is tested using the spark leak test method appropriate for the type of wire, a robust manner with no minimum spark leak or spark leak to ensure that the minimum length of the wire without spark leak is 150 m, more particularly 250 m, even more particularly 500 m It is clear that the thermoplastic composition should be applicable to the line. Spark leaks can be caused by defects in the line cladding, such as gaps such as pinholes, particulate matter and the like.

Defects may be introduced by the coating process or may originate in the thermoplastic composition. Defects can be introduced by the coating process through improper cleaning of the coating extruder or by interrupting the operation of the coating extruder for an extended period of time such that the thermoplastic composition forms gels and black stains. The material remaining from the previous coating can form particulates that create defects and spark leaks. The defects introduced in the thermoplastic composition can be reduced or eliminated by cleaning the coating extruder, in particular the part after the filter, and melt filtration of the thermoplastic composition.

Similarly, cleaning the melt mixing device, especially the compartment after the filter, can reduce or remove particulate matter and gels resulting from residual material from previous use of the compounding extruder.

A cross section of an exemplary wire is shown in FIG. 1. 1 shows a cladding 4 disposed on a conductor 2. In one embodiment, the coating 4 comprises a foamed thermoplastic composition. Perspective views of exemplary wires are shown in FIGS. 2 and 3. 2 shows a covering 4 disposed on a conductor 2 comprising a plurality of strands, an optional additional layer 6 disposed on the covering 4, and the conductor 2. In one embodiment, the coating 4 comprises a foamed thermoplastic composition. The conductor 2 may also comprise one conductor. 3 shows the cladding 4 and the intervening layer 6 disposed on one conductor 2. In one embodiment, the intervening layer 6 comprises a foamed composition. The conductor 2 may also comprise a number of strands.

In one embodiment, the wire is 0.15mm ² to 1.10mm has a coating material having a conductor with 0.15mm to 0.25mm thickness having a cross-sectional area of ^2, a total length of 13,500 to the case of the 15,500m wires, the individual length of up to 6, More particularly there are up to four individual lengths, more in particular up to three individual lengths, and each individual length is at least 150 m, more particularly at least 250 m and even more particularly at least 500 m. As used herein, individual length means a single length of line having both ends.

In another aspect, the wire is 0.30mm ² to 1.30mm has a coating material having a conductor with 0.19mm to 0.31mm thickness having a cross-sectional area of the ^second, in the case of a wire with a total length of 285 to 14,000m, the individual length of up to 6, More particularly there are up to four individual lengths, more in particular up to three individual lengths, and each individual length is at least 150 m, more particularly at least 250 m and even more particularly at least 500 m.

In another aspect, the wire is 1.20mm ² to 2.10mm has a coating material having a conductor with 0.29mm to 0.36mm thickness having a cross-sectional area of the ^second, in the case of a wire with a total length of 5,000 to 7,100m, the individual length of up to 6, More particularly there are up to four individual lengths, more in particular up to three individual lengths, and each individual length is at least 150 m, more particularly at least 250 m and even more particularly at least 500 m.

In another aspect, the wire is 2.90mm ² to 4.50mm has a coating material having a conductor and a 0.3mm to 0.8mm thick having the cross-sectional area of the ^second, when the total length of 2,500 to 5,000m line, the individual length of up to 6, more In particular there are no more than four individual lengths, more in particular no more than three individual lengths, each individual length being at least 150 m, more particularly at least 250 m, even more particularly at least 500 m.

The thermoplastic compositions disclosed herein comprise two or more phases, a polyolefin phase and a poly (arylene ether) phase. The polyolefin phase is a continuous phase. In some embodiments, the poly (arylene ether) phase can be dispersed on the polyolefin phase. Good compatibility between the phases can lead to improved physical properties including higher impact strength at lower temperatures and room temperature, better thermal aging, better flame retardancy and greater tensile extension. It is generally accepted that the appearance of the composition indicates the degree of compatibility or quality. Poly (arylene ether) of small, relatively uniform sized particles evenly distributed throughout the composition area exhibits good compatibility.

The thermoplastic compositions disclosed herein are essentially free of alkenyl aromatic resins, such as polystyrene or rubber modified polystyrene, also known as high impact polystyrene or HIPS. Essentially free of less than 10%, more particularly less than 7%, more particularly less than 5%, even more particularly less than 3% by weight, based on the combined weight of the poly (arylene ether), polyolefin and block copolymer It is defined to include alkenyl aromatic resins. In one embodiment, the composition is completely free of alkenyl aromatic resins. Surprisingly, the presence of alkenyl aromatic resins can negatively affect the compatibility between the poly (arylene ether) phase and the polyolefin phase.

In one embodiment, the composition has a flexural modulus of less than 8,000-18000 kg / cm ² (less than 800-1800 MPa). Within this range, the flexural modulus may be at least 10,000 kg / cm ² (1000 MPa), more particularly at least 12,000 kg / cm ² (1200 MPa). Also within this range, the flexural modulus may be 17,000 kg / cm ² (1700 MPa) or less, more particularly 16,000 kg / cm ² (1600 MPa) or less. Flexural modulus as disclosed herein is measured using ASTM D790-03 and a speed of 1.27 mm per minute. Flexural modulus values are the average of three samples. Samples for flexural modulus include injection pressures of 600 to 700 kg per force ² and 15 to 20 on Plastar Ti-80G ₂ from Toyo Machinery & Metal Co. LTD. It is formed using the holding time of seconds. The remaining molding conditions are shown in Table A.

In one embodiment, the wire meets or exceeds the requirements of ISO 6722, in particular the requirements for wear, grade A, B or C heat aging, chemical resistance and environmental cycles.

As used herein, "poly (arylene ether)" includes a number of structural units of the formula:

Where

Q ¹ and Q ² are each independently hydrogen, halogen, primary or secondary lower alkyl (eg alkyl containing 1 to 7 carbon atoms), phenyl, haloalkyl, aminoalkyl, alkenylalkyl, alkynyl Alkyl, hydrocarbonoxy, aryl and halohydrocarbonoxy, wherein at least two carbon atoms separate halogen and oxygen atoms.

In some embodiments, Q ¹ is each independently an alkyl or phenyl, for example, C _{1 -4} alkyl, Q ² are each independently hydrogen or methyl. The poly (arylene ether) may comprise a molecule having an aminoalkyl-containing end group, typically located in the ortho position relative to the hydroxy group. There is also a tetramethyl diphenylquinone (TMDQ) end group which is typically obtained from a reaction mixture in which tetramethyl diphenylquinone by-products are present.

The poly (arylene ether) may be in the form of a homopolymer, copolymer, graft copolymer, ionomer or block copolymer, and combinations comprising one or more of these. Poly (arylene ether) is a polyphenylene optionally comprising 2,6-dimethyl-1,4-phenylene ether units in combination with 2,3,6-trimethyl-1,4-phenylene ether units Contains ether.

Poly (arylene ether) is a monohydroxyaromatic compound such as 2,6-xyleneol, 2,3,6-trimethylphenol and 2,6-xyleneol and 2,3,6-trimethylphenol. By oxidative coupling in combination. Catalyst systems are generally used for such coupling, and they are generally heavy metal compounds, such as secondary amines, tertiary amines, halides or combinations of two or more of the foregoing, for example heavy metal compounds, for example It may contain copper, manganese or cobalt compounds.

In one embodiment, the poly (arylene ether) comprises a capped poly (arylene ether). Terminal hydroxy groups can be capped with a capping agent, for example by an acylation reaction. The capping agent selected is preferably one that produces a less reactive poly (arylene ether), thereby reducing or preventing the formation of gels or black spots during processing at crosslinking of polymer chains and elevated temperatures. Suitable capping agents are, for example, esters of salicylic acid, anthranilic acid or substituted derivatives thereof, and the like; Preference is given to esters of salicylic acid and in particular salicylic carbonate and linear polysalicylates. The term "ester of salicylic acid" as used herein includes compounds in which carboxy groups, hydroxy groups or both are esterified. Suitable salicylates are, for example, aryl salicylates such as phenyl salicylate, acetylsalicylic acid, salicylic carbonate and polysalicylates, and linear polysalicylates and cyclic compounds (eg disalicylates). And trisalicylate). In one embodiment, the capping agent is selected from salicylic carbonate and polysalicylates, in particular linear polysalicylates and combinations comprising one of the foregoing. Exemplary capped poly (arylene ether) and its preparation are disclosed in US Pat. No. 4,760,118 to White et al. And US Pat. No. 6,306,978 to Braat.

Capping of poly (arylene ether) with polysalicylates is also believed to reduce the amount of aminoalkyl end groups present in the poly (arylene ether) chain. Aminoalkyl groups are the result of oxidative coupling reactions with amines in the process of making poly (arylene ether). Aminoalkyl groups in the ortho position relative to the terminal hydroxy groups of the poly (arylene ether) may be susceptible to decomposition at high temperatures. Decomposition is believed to result in the regeneration of the primary or secondary amines and the regeneration of the quinone metade end groups, which may also produce 2,6-dialkyl-1-hydroxyphenyl end groups. Capping poly (arylene ether) containing aminoalkyl groups with polysalicylates removes these amino groups to form capped terminal hydroxy groups in the polymer chain and 2-hydroxy-N, N-alkylbenzamine It is thought to form (salicylicamide). Removal of amino groups and capping provides a poly (arylene ether) that is more stable at high temperatures, producing less degradation products during processing of the poly (arylene ether).

Poly (arylene ether) is 3,000-40,000 g (g) per mole as measured by gel permeation chromatography using a single dispersed polystyrene standard, styrene divinyl benzene gel and a sample at a concentration of 1 mg per ml of chloroform at 40 ° C. Per mole) and a weight average molecular weight between 5,000 and 80,000 g / mol. The combination of poly (arylene ether) or poly (arylene ether) may have an initial intrinsic viscosity of at least 0.25 dl / g as measured in chloroform at 25 ° C. Initial intrinsic viscosity is defined as the intrinsic viscosity of poly (arylene ether) before melt mixing with other components of the composition, and final intrinsic viscosity is defined as the intrinsic viscosity of poly (arylene ether) after melt mixing with other components of the composition. do. As will be appreciated by those skilled in the art, the viscosity of the poly (arylene ether) can be up to 30% higher after melt mixing. The percent increase can be calculated as (final intrinsic viscosity-initial intrinsic viscosity) / initial intrinsic viscosity. When two initial intrinsic viscosities are used, the determination of the exact ratio will depend somewhat on the exact intrinsic viscosity and the desired ultimate properties of the poly (arylene ether) used.

There may be substantially no particulate impurities visible in the poly (arylene ether) used in the preparation of the thermoplastic composition. In one embodiment, the poly (arylene ether) is substantially free of particulate impurities greater than 15 micrometers in diameter. As used herein, the term “substantially free of visible particulate impurities”, when applied to poly (arylene ether), 10 g of poly (arylene ether) sample dissolved in 50 ml of chloroform (CHCl ₃ ) in a light box. This means less than 5 visible specks appear. Particles visible to the naked eye are typically those having a diameter of 40 μm or more. As used herein, the term “substantially free of particulate impurities greater than 15 μm” means that 40 g of poly (arylene ether) sample dissolved in 400 ml of CHCl ₃ is passed through the analyzer at a flow rate of 1 ml per minute (± 5%). Based on the average of five samples in 20 ml amounts of polymer material, it means that the number of microparticles having a size of 15 μm per gram is less than 50 as measured by a Pacific Instruments ABS2 analyzer.

The thermoplastic composition comprises poly (arylene ether) in an amount of 30 to 65% by weight relative to the total weight of the composition. Within this range, the poly (arylene ether) may be at least 40% by weight, more particularly at least 45% by weight. Also within this range the amount of poly (arylene ether) may be up to 55% by weight.

Polyolefins have the general formula C _n H _2n and include polyethylene, polypropylene and polyisobutylene. Exemplary homopolymers are polyethylene, LLDPE (linear low density polyethylene), HDPE (high density polyethylene) and MDPE (medium density polyethylene) and isotactic polypropylene. Polyolefin resins of this chemical structure and methods for their preparation are well known in the art, for example, US Pat. Nos. 2,933,480, 3,093,621, 3,211,709, 3,646,168, 3,790,519, 3,884,993, 3,894,999 4,059,654, 4,166,055 and 4,584,334.

Also copolymers of ethylene and alpha olefins (for example propylene, octene and 4-methylpentene-1), and also copolymers of polyolefins such as copolymers of ethylene and one or more rubbers and copolymers of propylene and one or more rubbers Can be used. Ethylene and a C _{3 -} C ₁₀ mono-olefins and non-conjugated diene copolymer (herein referred to as EPDM copolymers) are also suitable. Examples of suitable C ₃ -C ₁₀ monoolefins for EPDM copolymers include propylene, 1-butene, 2-butene, 1-pentene, 2-pentene, 1-hexene, 2-hexene and 3-hexene. Suitable dienes include 1,4-hexadiene and monocyclic and polycyclic dienes. The molar ratio of ethylene to other C ₃ -C ₁₀ monoolefin monomers is 95: 5 to 5:95 and diene units are present in amounts of 0.1 to 10 mole percent. EPDM copolymers can be functionalized with acyl groups or electrophilic groups to be grafted with polyphenylene ether as disclosed in US Pat. No. 5,258,455.

The thermoplastic composition may comprise one homopolymer, a combination of homopolymers, one copolymer, a combination of copolymers or a combination comprising a homopolymer and a copolymer.

In one embodiment, the polyolefin is selected from the group consisting of polypropylene, high density polyethylene, and combinations of polypropylene and high density polyethylene. The polypropylene may be a monopolypropylene or polypropylene copolymer. Copolymers of polypropylene and rubber or block copolymers are often referred to as impact modified polypropylenes. Such copolymers are typically heterophasic and have compartments of each component that are long enough to have both amorphous and crystalline phases. Polypropylene may also include combinations of homopolymers and copolymers, combinations of homopolymers having different melting temperatures, or combinations of homopolymers having different melt flow rates.

In one embodiment, the polypropylene includes crystalline polypropylene, such as isotactic polypropylene. Crystalline polypropylene is defined as polypropylene having a crystalline content of at least 20%, more particularly at least 25%, even more particularly at least 30%. Crystallinity can be measured by differential scanning calorimetry (DSC).

In some embodiments, the polypropylene has a melting temperature of at least 134 ° C., more particularly at least 140 ° C., even more particularly at least 145 ° C.

Polypropylene has a melt flow rate (MFR) of at least 0.4 g and at most 15 g per 10 minutes. Within this range the melt flow rate is greater than 0.6 g per 10 minutes. Also within this range the melt flow rate is 10 g / 10 minutes or less, more particularly 6 g / 10 minutes or less, and more particularly 5 g / 10 minutes or less. Melt flow rate can be measured according to ASTM D1238 using powdered or pelletized polypropylene, a load of 2.16 kg and a temperature of 230 ° C.

The high density polyethylene can be homogeneous polyethylene or polyethylene copolymer. High density polyethylene may also include combinations of homopolymers and copolymers, combinations of homopolymers having different melting temperatures or combinations of homopolymers having different melt flow rates and densities of generally 0.941 to 0.965 g / cm ³ . .

In some embodiments, the high density polyethylene has a melting temperature of at least 124 ° C, more particularly at least 126 ° C, even more particularly at least 128 ° C.

High density polypropylene has a melt flow rate (MFR) of at least 0.10 g and at most 15 g per 10 minutes. Within this range the melt flow rate is greater than 1.0 g per 10 minutes. Also within this range the melt flow rate is 10 g / 10 minutes or less, more particularly 6 g / 10 minutes or less, and more particularly 5 g / 10 minutes or less. Melt flow rate can be measured according to ASTM D1238 using powder or pelletized polyethylene, a load of 2.16 kg and a temperature of 190 ° C.

The composition may comprise polyolefins in an amount of 15 to 35 weight percent based on the total weight of the composition. Within this range the amount of polyolefin is at least 17% by weight, more particularly at least 20% by weight. Also within this range, the amount of polyolefin is 33% by weight or less, more particularly 30% by weight or less.

In one embodiment the polyolefin comprises high density polyethylene (HDPE) and polypropylene, and the weight basis amount of HDPE is less than the weight amount polypropylene weight.

In one embodiment, the polyolefin is present in a weighted amount less than the poly (arylene ether) weighted amount.

Polymeric compatibilizers are resins and additives that improve the compatibility between the polyolefin phase and the poly (arylene ether) phase. Polymeric compatibilizers include block copolymers, polypropylene-polystyrene graft copolymers, and combinations of block copolymers and polypropylene-polystyrene graft copolymers as disclosed below.

As used herein and throughout the specification, the term "block copolymer" means a single block copolymer or a combination of block copolymers. The block copolymer comprises at least one block (A) comprising repeating aryl alkylene units and at least one block (B) comprising repeating alkylene units. The arrangement of blocks (A) and (B) can be linear or so-called radial teleblock structures with branched chains. A-B-A terblock copolymers have two blocks A comprising repeating aryl alkylene units. The suspended aryl moiety of the aryl alkylene unit is monocyclic or polycyclic, and may have a substituent at any available position of the cyclic moiety. Suitable substituents include alkyl groups having 1 to 4 carbons. Exemplary aryl alkylene units are phenylethylene, which is shown in Formula 2:

Block A may further comprise alkylene units having 2 to 15 carbons so long as the amount of aryl alkylene units exceeds the amount of alkylene units.

Block B comprises repeating alkylene units having 2 to 15 carbons, for example ethylene, propylene, butylene or combinations of two or more thereof. Block B may further comprise aryl alkylene units as long as the amount of alkylene units exceeds the amount of aryl alkylene units.

Each block A may have the same or different molecular weight as another block A. Similarly, each block B may have the same or different molecular weight as the other block B. Block copolymers can be functionalized by reaction with alpha-beta unsaturated carboxylic acids.

In one embodiment, the B block comprises a copolymer of aryl alkylene units and alkylene units of 2 to 15 carbon atoms, such as ethylene, propylene, butylene or combinations of two or more thereof. The B block may further comprise some unsaturated non-aromatic carbon-carbon bonds.

The B block can be a controlled distribution copolymer. As used herein, “controlled distribution” refers to the well of either monomer, as shown by the presence of only a single glass transition temperature (Tg) which is the median between the Tg of either homopolymer or by a proton nuclear magnetic resonance method. Any given single monomer having no defined block and having a maximum number of 20 units on average is defined as meaning a molecular structure that is “followed”. If the B blocks comprise controlled distribution copolymers, each A block can have an average molecular weight of 3000 to 60,000 g / mol, and each B block can be 30,000 to 300,000 g / mol as measured using light scattering techniques. It may have an average molecular weight of. If the B block is a controlled distribution copolymer, each B block includes one or more terminal regions adjacent to the A block rich in alkylene units, and a region not adjacent to the A block rich in aryl alkylene units. The total amount of aryl alkylene units is 15 to 75% by weight, based on the total weight of the block copolymer. The weight ratio of alkylene units to aryl alkylene units in the B block may be 5: 1 to 1: 2. Exemplary block copolymers are further disclosed in US Patent Application No. 2003/181584 and are commercially available from Kraton Polymers under the trade name KRATON. Exemplary grades are A-RP6936 and A-RP6935.

Repeated aryl alkylene units result from the polymerization of aryl alkylene monomers, for example styrene. Repeating alkylene units are produced from hydrogenation of repeating unsaturated units derived from dienes such as butadiene. Butadiene may comprise 1,4-butadiene and / or 1,2-butadiene. The B block may further comprise some unsaturated non-aromatic carbon-carbon bonds.

Exemplary block copolymers are polyphenylethylene-poly (ethylene / propylene) -polyphenylethylene (often referred to as polystyrene-poly (ethylene / propylene) -polystyrene) and polyphenylethylene-poly (ethylene / butylene) -poly Phenylethylene (often referred to as polystyrene-poly (ethylene / butylene) -polystyrene).

In one embodiment, the polymeric compatibilizer comprises two block copolymers. The first block copolymer has an aryl alkylene content of at least 50% by weight based on the total weight of the first block copolymer. The second block copolymer has an aryl alkylene content of up to 50% by weight based on the total weight of the second block copolymer. An exemplary combination of block copolymers is a first polyphenylethylene-poly (ethylene / butylene) -polyphenylethylene having a phenylethylene content of 15% to 40% by weight based on the total weight of the block copolymer Second poly phenylethylene-poly (ethylene / butylene) -polyphenylethylene can be used having a phenylethylene content of 55% to 70% by weight based on the total weight of the copolymer. Exemplary block copolymers having an aryl alkylene content of more than 50% by weight are commercially available from Asahi under the tradename TUFTEC and having a grade name of H1043, and also by the Kuraray tradename Septon. Some grades are commercially available). Exemplary block copolymers having an aryl alkylene content of less than 50% by weight are commercially available from Kraton Polymers under the trade name Kraton and are G-1701, G-1702, G-1730, G-1641, G-1650. , G-1651, G-1652, G-1657, A-RP6936 and A-RP6935.

In one embodiment, the polymeric compatibilizer comprises a diblock block copolymer and a tertiary block block copolymer.

In some embodiments, the block copolymers have a number average molecular weight of 5,000 to 1,000,000 g / mol as measured by gel permeation chromatography (GPC) using polystyrene standards. Within this range, the number average molecular weight may be at least 10,000 g / mol, more particularly at least 30,000 g / mol, more particularly at least 45,000 g / mol. Also within this range, the number average molecular weight may be up to 800,000 g / mol, more particularly up to 700,000 g / mol, or even more particularly up to 650,000 g / mol.

Polypropylene-polystyrene graft copolymers are defined herein as graft copolymers having a polypropylene polymer backbone and one or more styrene polymer grafts.

The propylene polymer material forming the backbone or substrate of the polypropylene-polystyrene graft copolymer includes (a) a homopolymer of propylene; (b) propylene and random copolymers of olefins selected from the group consisting of ethylene and C ₄ -C ₁₀ olefins, provided that the polymerized ethylene content is up to about 10% by weight, preferably about 4% by weight, when the olefin is ethylene Up to and wherein the olefin is a C ₄ -C ₁₀ olefin, the polymerized content of the C ₄ -C ₁₀ olefin is about 20% by weight or less, preferably about 16% by weight or less); (c) random terpolymers of propylene and at least two olefins selected from the group consisting of ethylene and C ₄ -C ₁₀ alpha-olefins, provided that the polymerized C ₄ -C ₁₀ alpha-olefin content is up to about 20% by weight, Preferably about 16% by weight or less and if ethylene is one of the olefins, the polymerized ethylene content is about 5% by weight or less, preferably about 4% by weight or less); Or (d) homopolymers or random copolymers of impact-modified propylene, not only by physical blending, but also with ethylene-propylene monomer rubber in the reactor (the ethylene-propylene monomer rubber content of the modified polymer is from about 5 to about 30 weight %, And the ethylene content of the rubber is about 7 to about 70 weight percent, preferably about 10 to about 40 weight percent). C ₄ -C ₁₀ olefins are linear and branched C ₄ -C ₁₀ alpha-olefins, for example 1-butene, 1-pentene, 3-methyl-1-butene, 4-methyl-1-pentene, 1- Hexene, 3,4-dimethyl-1-butene, 1-heptene, 1-octene, 3-methyl-hexene and the like. Propylene homopolymers and impact-modified homopolymers are preferred propylene polymer materials. Although not preferred, propylene homopolymers and random copolymers impact modified with ethylene-propylene-diene monomer rubbers having a diene content of about 2 to about 8% by weight may also be used as the propylene polymer material. Suitable dienes include dicyclopentadiene, 1,6-hexadiene, ethylidene norbornene and the like.

The term "styrene polymer" as used to refer to a graft polymer present on the main chain of propylene polymer material in a polypropylene-polystyrene graft copolymer refers to (a) styrene, or one or more C ₁ -C ₄ linear or branched alkyl ring substituents. Homopolymers of alkyl styrenes, in particular p-alkyl styrenes; (b) copolymers of (a) all proportions of monomers with other monomers; And (c) a copolymer of at least one monomer (a) with an alpha-methyl derivative thereof, such as alpha-methylstyrene, wherein the alpha-methyl derivative comprises from about 1 to about 40 weight percent of the copolymer. Means.

The polypropylene-polystyrene graft copolymer may comprise about 10 to about 90 weight percent propylene polymer backbone and about 90 to about 10 weight percent styrene polymer graft. Within this range, the propylene polymer backbone may comprise at least about 20% by weight of the total graft copolymer, and the propylene polymer backbone may comprise up to about 40% by weight of the total graft copolymer. Also within this range, the styrene polymer graft may comprise at least about 50%, more particularly at least about 60%, by weight of the total graft copolymer.

The preparation of polypropylene-polystyrene graft copolymers is disclosed, for example, in US Pat. No. 4,990,558 to DeNicola, Jr. Suitable polypropylene-polystyrene graft copolymers are also commercially available, for example P1045H1 and P1085H1 from Basell.

The polymerization compatibilizer is present in an amount of from 2 to 30 weight percent, based on the total weight of the composition. Within this range, the polymerization compatibilizer may be present in an amount of at least 4%, more particularly at least 6% by weight relative to the total weight of the composition. Also within this range, the polymerization compatibilizer may be present in an amount of up to 18%, more particularly up to 16%, even more particularly up to 14% by weight relative to the total weight of the composition.

Exemplary flame retardants include melamine (CAS No. 108-78-1), melamine cyanurate (CAS No. 37640-57-6), melamine phosphate (CAS No. 20208-95-1), melamine pyrophosphate (CAS No. 15541-60-3), melamine polyphosphate (CAS No. 218768-84-4), melam, melem, melon, zinc borate (CAS No. 1332-07-6), boron phosphate, red (CAS No. 7723-14-0), organophosphate esters, monoammonium phosphate (CAS No. 7722-76-1), diammonium phosphate (CAS No. 7783-28-0), alkyl phosphonates (CAS No. 78-38 -6 and 78-40-0), metal dialkyl phosphinates, ammonium polyphosphate (CAS No. 68333-79-9), low melting glass and combinations of two or more of the foregoing flame retardants.

Exemplary organic phosphate ester flame retardants include phenyl groups, substituted phenyl groups, or combinations of phenyl groups and substituted phenyl groups, bis-aryl phosphate esters based on resorcinol, such as resorcinol bis-die Phenylphosphates, and also those based on bis-phenols, such as, for example, bis-phenol A bis-diphenylphosphate. In one embodiment, the organic phosphate ester is tris (alkylphenyl) phosphate (e.g. CAS No. 89492-23-9 or CAS No. 78- 33-1), resorcinol bis-diphenylphosphate (e.g. , CAS No. 57583-54-7), bis-phenol A bis-diphenylphosphate (e.g. CAS No. 181028-79-5), triphenyl phosphate (e.g. CAS No. 115-86- 6) tris (isopropylphenyl) phosphate (eg, CAS No. 68937-41-7) and mixtures of two or more of the foregoing organic phosphate esters.

In one embodiment, the organic phosphate ester comprises bis-aryl phosphate of Formula 3:

Where

R, R ⁵ and R ⁶ are each independently an alkyl group having 1 to 5 carbon atoms,

R ¹ to R ⁴ are independently alkyl, aryl, arylalkyl or alkylaryl groups having 1 to 10 carbon atoms,

n is an integer from 1 to 25,

s1 and s2 are independently an integer of 0-2.

In some embodiments, OR ¹ , OR ² , OR ³ And OR ⁴ are independently derived from phenol, monoalkylphenol, dialkylphenol or trialkylphenol.

As will be readily appreciated by those skilled in the art, bis-aryl phosphates are derived from bisphenols. Exemplary bisphenols include 2,2-bis (4-hydroxyphenyl) propane (so-called bisphenol A), 2,2-bis (4-hydroxy-3-methylphenyl) propane, bis (4-hydroxyphenyl) methane, Bis (4-hydroxy-3,5-dimethylphenyl) methane and 1,1-bis (4-hydroxyphenyl) ethane. In one embodiment, the bisphenol comprises bisphenol A.

Organic phosphate esters can have different molecular weights, making it difficult to measure the amount of different organic phosphate esters used in thermoplastic compositions. In one embodiment, the amount of phosphorus as a result of the organic phosphate ester is from 0.8% to 1.2% by weight relative to the total weight of the composition.

If present in the thermoplastic composition, the amount of flame retardant is sufficient for the wire to have a burn down time of less than 70 seconds when tested according to the flame progression procedure contained in ISO 6722.

In one embodiment, the flame retardant comprises an organic phosphate ester present in an amount of from 5 to 18% by weight relative to the total weight of the composition. Within this range, the amount of organic phosphate ester may be at least 7% by weight, more particularly at least 9% by weight. Within this range, the amount of organic phosphate ester may be up to 16% by weight, more particularly up to 14% by weight.

In addition, the composition may contain various additives, such as antioxidants; Fillers and reinforcing agents having an average particle size of 10 micrometers or less, such as silicates, TiO ₂ , fibers, glass fibers, glass spheres, calcium carbonate, talc and mica; Mold release agent; UV absorbers; Stabilizers such as light stabilizers and the like; slush; Plasticizers; Pigments; dyes; coloring agent; Antistatic agent; blowing agent; Blowing agents; It may optionally contain a combination comprising a metal deactivator and one or more additives described above.

The composition and wires are further illustrated by the following non-limiting examples.

The following examples were made using the materials listed in Table 2:

The thermoplastic composition was prepared by melt mixing the components in a twin screw extruder. PPE and block copolymer were added to the neck of the feeder and PP was added downstream of the second opening of the extruder. Organic phosphate esters were added by liquid injector in the second half of the extruder. The composition was produced by either no filter (no mesh) or one or two filters with different opening sizes as shown in Tables 4 and 5. The material was pelleted at the extruder end using strand pelletization. The composition is shown in Table 3.

The thermoplastic composition was dried at 80 ° C. for 3-4 hours prior to extrusion with the conductor to form a wire. The conductor was a copper wire with a conductor size of 0.2 mm ² . The wire was generated using a line speed of 250 meters per minute. The thermoplastic composition was preheated at 100 ° C. and extruded onto the conductor at 275 ° C. by melt filtration using a filter without filter (no mesh) or with an opening size in μm as described in Tables 4 and 5. The coating had a thickness of 0.2 mm (Table 4) and 0.15 mm (Table 5). 5KV over a length of 1250m using a high frequency AC spark tester, model number HF-ISA / BD-12, available from The Clinton Instrument Company, Clinton, Connecticut Was tested for spark leakage. The number of spark leaks for each set of manufacturing conditions is shown in Tables 4 and 5 below:

As can be seen from Tables 4 and 5, in particular, as the thickness of the coating decreases, in order to produce wires with little or no spark leakage, during melt mixing, during extrusion coating, or during melt coating and extrusion coating, Filtration is essential.

While the present invention has been described with reference to various embodiments, those skilled in the art will understand that various changes and elements thereof may be substituted for equivalents without departing from the scope of the present invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Thus, the invention is not limited to the particular embodiments disclosed as the best mode contemplated for carrying out the invention, but the invention will include all embodiments falling within the scope of the appended claims.

All mentioned patents, patent applications and other references are incorporated herein by reference in their entirety.

Claims (21)

conductor; And A wire comprising a coating material disposed on the conductor, the thermoplastic composition comprising (i) poly (arylene ether), (ii) polyolefin, and (iii) a polymerization compatibilizer, Wherein the conductor has a cross-sectional area of 0.15mm ² to 1.00mm ^2, The coating material has a thickness of 0.15 to 0.25 mm, For wires of 13,500 to 15,500 m, there are no more than six individual lengths of wire, and each individual length of wire has a length of at least 150 m. conductor; And A wire comprising a coating material disposed on the conductor, the thermoplastic composition comprising (i) poly (arylene ether), (ii) polyolefin, and (iii) a polymerization compatibilizer, Wherein the conductor has a cross-sectional area of 0.30mm ² to 1.30mm ^2, The coating material has a thickness of 0.15 to 0.35 mm, For wires of 8,500 to 14,500 m, there are no more than six individual lengths of wire, and each individual length of wire has a length of at least 150 m. conductor; And A wire comprising a coating material disposed on the conductor, the thermoplastic composition comprising (i) poly (arylene ether), (ii) polyolefin, and (iii) a polymerization compatibilizer, Wherein the conductor has a cross-sectional area of 1.20mm ² to 2.10mm ^2, The coating material has a thickness of 0.29 to 0.36 mm, For wires of 5,000 to 7,100 m, there are no more than six individual lengths of wire, and each individual length of wire has a length of at least 150 m. conductor; And A wire comprising a coating material disposed on the conductor, the thermoplastic composition comprising (i) poly (arylene ether), (ii) polyolefin, and (iii) a polymerization compatibilizer, The conductor has a cross-sectional area of 2.90 mm ² to 4.50 mm ² , The coating material has a thickness of 0.3 to 0.8 mm, For wires of 2,500 to 5,000 m, there are no more than six individual lengths of wires, and each individual length of wires has a length of at least 150 m. conductor; And A wire comprising a coating material disposed on the conductor, the thermoplastic composition comprising (i) poly (arylene ether), (ii) polyolefin, and (iii) a polymerization compatibilizer, For lines 2,500 to 15,500 m, wires with up to 5 spark leaks. Melt mixing poly (arylene ether), polyolefin, and a polymerization compatibilizer to form a first mixture; Melt filtering the first mixture through a first filter having an opening having a diameter of 20 to 150 μm to form a first filtered mixture; Melt filtering the first filtered mixture through a second filter having an opening having a diameter of 20 to 150 μm to form a second filtered mixture; And Applying the second filtered mixture to a conductor Including, a method for producing a coating or wire for the conductor. Melt filtration of the composition comprising poly (arylene ether), polyolefin, and a polymerization compatibilizer to form a filtered composition; And Applying the filtered composition to a conductor to form a wire having less than 5 spark leaks per wire of 2500 to 15,500 m It includes, the manufacturing method of the wire. A coating material comprising a thermoplastic composition comprising (i) poly (arylene ether), (ii) polyolefin, and (iii) a polymerization compatibilizer, Furthermore, the covering comprising the covering disposed on the conductor has up to five spark leaks per line of 2500 to 15,500 m. A coating material comprising a thermoplastic composition comprising (i) poly (arylene ether), (ii) polyolefin, and (iii) a polymerization compatibilizer, A coating material free of particulate impurities substantially visible in the thermoplastic composition. Melt mixing poly (arylene ether), polyolefin, and a polymerization compatibilizer to form a mixture; And Melt filtering the mixture through a filter A coating material for a conductor comprising a thermoplastic composition produced by the method comprising a. Melt mixing poly (arylene ether), polyolefin, and a polymerization compatibilizer to form a first mixture; Melt filtration of the first mixture through a first filter; Melt filtering the first filtered mixture through a second filter to form a second filtered mixture Covering the conductor, comprising a thermoplastic composition produced by the method comprising a. The method of claim 11, The first filter has an opening having a diameter of 20 μm to 150 μm, the second filter has an opening having a diameter of 20 μm to 150 μm, or both the first filter and the second filter A coating material having an opening having a diameter of 20 µm to 150 µm. The method of claim 11, The covering material has a thickness, and the said 2nd filter has an opening which has a maximum diameter of half or less of coating material thickness. The method according to any one of claims 1 to 13, Wire or cladding, wherein the conductor comprises a single strand or a plurality of strands. The method according to any one of claims 1 to 14, A wire or sheathing material wherein said polyolefin is selected from the group consisting of polypropylene, high density polyethylene and a combination of polypropylene and high density polyethylene. The method according to any one of claims 1 to 15, A wire or covering material comprising a block copolymer having a block wherein the polymerization compatibilizer is a controlled distribution copolymer. The method according to any one of claims 1 to 16, The polymeric compatibilizer has a first block copolymer having an aryl alkylene content of at least 50% by weight based on the total weight of the first block copolymer, and up to 50% by weight of aryl alkyl based on the total weight of the second block copolymer A wire or sheath comprising a second block copolymer having a lene content. The method according to any one of claims 1 to 17, Wire or covering material wherein the polymerization compatibilizer comprises a binary block copolymer and a terpolymer block copolymer. The method according to any one of claims 1 to 18, A wire or coating material wherein the polymerization compatibilizer comprises a polypropylene-polystyrene graft copolymer. The method according to any one of claims 1 to 19, Wire or cladding wherein the thermoplastic composition further comprises a flame retardant. The method according to any one of claims 1 to 20, Wherein the thermoplastic composition comprises a weight-based amount of polyolefin that is less than the weight-based amount of poly (arylene ether) based on the combined weight of polyolefin and poly (arylene ether).

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