Patent Application
20130264091
The present invention relates to an insulated wire and a cable.
Accompanying the development of electronic devices using frequencies in the gigahertz band in recent years, USB 3.0 cables, HDMI cables, InfiniBand cables, micro USB cables and other high-speed transmission cables used to connect these devices are being required to have superior dielectric characteristics in the gigahertz band.
The cable described in, for example, Patent Document 1 indicated below is known to be such a transmission cable. Patent Document 1 indicated below proposes that superior dielectric characteristics are obtained by using, as an insulating layer that covers a conductor, a material obtained by incorporating a phenol-based antioxidant not having a hindered phenol structure in an olefin-based resin.
Patent Document 1: Japanese Patent Application Laid-open No. 2009-81132
However, the cable described in the above-mentioned Patent Document 1 had the problems indicated below.
Namely, in the case of using polyethylene for the olefin-based resin of the insulating layer, there are limitations on polyethylene for allowing the obtaining of superior dielectric characteristics in high frequency bands. Therefore, the insulating layer has been used in the form of a foamed body in order to obtain superior dielectric characteristics while using polyethylene for the olefin-based resin of the insulating layer. However, in the case of the insulating layer being in the form of a foamed body, it was necessary to reduce the thickness of the insulating layer accompanying reductions in diameter of the transmission cable. In this case, mechanical strength of the insulating layer decreases and the insulating layer is easily crushed by lateral pressure. Consequently, it is difficult to impart heat resistance at the level of UL90° C. to the insulating layer with polyethylene. Therefore, it was considered to use a propylene-based resin having a higher melting point instead of polyethylene for the olefin-based resin from the viewpoint of imparting heat resistance at the level of UL90° C. to the insulating layer. However, in the case of an insulating layer that contains a propylene-based resin, there are cases in which dielectric tangent in the gigahertz band cannot be said to be sufficiently small, thereby leaving room for improvement with respect to dielectric characteristics in the gigahertz band.
Therefore, a first object of the present invention is to provide an insulated wire and a cable capable of realizing superior dielectric characteristics in the gigahertz band as well as superior heat aging resistance characteristics.
In addition, a second object of the present invention is to provide an insulated wire and a cable capable of realizing superior dielectric characteristics in the gigahertz band as well as superior crush resistance and heat resistance.
The inventor of the present invention conducted extensive studies to achieve the aforementioned first object. As a result, the inventor of the present invention considered the following. Namely, even if using a propylene-based resin, propylene-based resins synthesized using a general-purpose catalyst such as a Ziegler-Natta catalyst include propylene-based resins having a broad molecular weight distribution and low molecular weight. These low molecular weight propylene-based resins are susceptible to the occurrence of molecular vibration at high frequencies. Consequently, the inventor of the present invention considered that even if using a propylene-based resin, propylene-based resins synthesized using a general-purpose catalyst such as a Ziegler-Natta catalyst are susceptible to the occurrence of heat loss, and that this causes an increase in dielectric tangent at high frequencies. Therefore, the inventor of the present invention conducted additional extensive studies. As a result, it was found that, in addition to using a propylene-based copolymer synthesized using a metallocene catalyst as a propylene-based copolymer, by incorporating an antioxidant having a specific structure in the propylene-based copolymer at a prescribed ratio, the above-mentioned first object can be achieved, thereby leading to completion of the first aspect of the present invention.
Namely, an insulated wire according to the first aspect of the present invention is an insulated wire provided with a conductor and an insulating layer that covers the conductor, wherein the insulating layer contains a propylene-based copolymer obtained by synthesis using a metallocene catalyst and an antioxidant having a chemical structure that differs from a hindered phenol structure, and the antioxidant is incorporated at a ratio of not less than 0.01 parts by mass to less than 1.5 parts by mass based on 100 parts by mass of the propylene-based copolymer.
According to this insulated wire, the propylene-based copolymer contained in the insulating layer is a propylene-based copolymer obtained by synthesis using a metallocene catalyst. Consequently, the width of molecular weight distribution can be narrowed in comparison with propylene-based copolymers synthesized using a general-purpose catalyst such as a Ziegler-Natta catalyst. Consequently, the ratio of low molecular weight propylene-based copolymers in the insulating layer, which causes molecular vibration at high frequencies and which are thought to be a factor increasing a dielectric tangent, can be adequately reduced. In addition, propylene-based copolymers are typically susceptible to oxidative degradation due to contact with the conductor and contain easily degradable tertiary carbons. Consequently, the molecules in propylene-based copolymers are easily severed. In this point, the antioxidant in the present invention having a chemical structure that differs from a hindered phenol structure is incorporated at a ratio of not less than 0.01 parts by mass to less than 1.5 parts by mass based on 100 parts by mass of the propylene-based copolymer. Consequently, degradation of the propylene-based copolymer can be adequately inhibited. Accordingly, according to the insulated wire according to the first aspect of the present invention, superior dielectric characteristics in the gigahertz band and superior heat aging resistance characteristics can be realized.
In the above-mentioned insulated wire, it is preferable that the insulating layer further contain a metal deactivator having a chemical structure that differs from a hindered phenol structure, and the metal deactivator be incorporated at a ratio of not less than 0.01 parts by mass to less than 1.5 parts by mass based on 100 parts by mass of the propylene-based copolymer.
In this case, heat aging resistance characteristics of the insulated wire are further improved.
In the insulated wire according to the first aspect of the present invention, the propylene-based copolymer is preferably an ethylene-propylene copolymer.
In this case, in comparison with the case of using a propylene-based copolymer other than an ethylene-propylene copolymer, in addition to obtaining better strength and heat resistance, more suitable flexibility is obtained.
In the insulated wire according to the first aspect of the present invention, the propylene-based copolymer has a melting point of 125° C. to 145° C.
If the melting point of the propylene-based copolymer is within the above-mentioned range, more adequate heat resistance can be obtained in comparison with the melting point of the propylene-based copolymer being lower than 125° C. In addition, if the melting point of the propylene-based copolymer is within the above-mentioned range, better dielectric characteristics can be obtained, since crystallinity of the propylene-based copolymer is increased. In addition, better flexibility is obtained in comparison with the case of the melting point of the propylene-based copolymer exceeding 145° C.
In the insulated wire according to the first aspect of the present invention, the above-mentioned antioxidant is preferably a semi-hindered phenol-based antioxidant or less-hindered phenol-based antioxidant.
In this case, in addition to obtaining more adequate heat aging resistance characteristics, better dielectric characteristics can be obtained in comparison with the case of using an antioxidant other than a semi-hindered phenol-based antioxidant or less-hindered phenol-based antioxidant.
In addition, the inventor of the present invention conducted extensive studies to achieve the above-mentioned, second, object. As a result, the inventor of the present invention considered the following. Namely, as a result of ethylene and butene present in a propylene-based copolymer inhibiting crystallization of propylene, the resulting amorphous portion is susceptible to molecular vibration at high frequencies. Consequently, the inventor of the present invention considered that the propylene-based copolymer is susceptible to the occurrence of heat loss, and this might cause an increase in dielectric tangent at high, frequencies. Therefore, the inventor of the present invention conducted additional extensive studies. As a result, it was found that, by setting the melting point of the propylene-based copolymer to a prescribed range, setting the total content of ethylene and butene in the propylene-based copolymer to a prescribed value or less, and preventing the content of butene in the propylene-based copolymer from exceeding a prescribed value, the above-mentioned second object can be achieved, thereby leading to completion of the second aspect of the present invention.
Namely, an insulated wire according to the second aspect of the present invention is an insulated wire provided with a conductor and an insulating layer that, covers the conductor, wherein the insulating layer contains a propylene-based copolymer having a melting point of 125° C. to 145° C., the total content of ethylene and butene in the propylene-based copolymer is 7% by mass or less, and the content of butene in the propylene-based copolymer does not exceed 2% by mass.
According to this insulated wire, superior dielectric characteristics in the gigahertz band and superior crush resistance and heat resistance can be realized.
Moreover, the inventor of the present invention conducted extensive studies to achieve the above-mentioned second object. As a result, the inventor of the present invention noticed that there is a correlation between the interval between the portion of the peak of the heat of melting and the portion of the peak of the heat of crystallization observed, in a DSC curve of a propylene-based copolymer, and dielectric characteristics in the gigahertz band. Therefore, the inventor of the present invention conducted additional extensive studies. As a result, the inventor of the present invention found that, by setting the melting point, of the propylene-based copolymer to a prescribed range and setting the difference between, the melting point determined from the portion of the peak of the neat, of melting and the crystallization peak temperature determined from the portion of the peak of the heat of crystallization to a prescribed range, the above-mentioned second object can be achieved, thereby leading to completion of a third aspect of the present invention.
Namely, an insulated, wire according to the third aspect of the present invention is an insulated wire provided with a conductor and an insulating layer that covers the conductor, wherein the insulating layer contains a propylene-based copolymer having a melting point of 125° C. to 145° C., and the propylene-based copolymer satisfies the following equation:
melting point−crystallization peak temperature=30° C. to 40° C.
According to this insulated wire, superior dielectric characteristics in the gigahertz band as well as superior crush resistance and heat resistance can be realized.
In the insulated wires according to the second and third aspects of the present invention, the above-mentioned propylene-based copolymer is preferably a propylene-based copolymer obtained by synthesis using a metallocene catalyst.
In this case, the width of molecular weight distribution can be narrowed in comparison with propylene-based copolymers synthesized using a general-purpose catalyst such as a Ziegler-Natta catalyst. As a result, the ratio of low molecular weight components susceptible to the occurrence of molecular vibration at high frequencies can be further reduced, and increases in dielectric tangent caused by low molecular weight components can be adequately inhibited.
In the insulated wires according to the second and third aspects of the present invention, the above-mentioned propylene-based copolymer is preferably a random copolymer.
In this case, the melting point of the propylene-based copolymer can be lowered further and flexibility of the insulated wire can be further improved in comparison with the case in which the propylene-based copolymer is a block copolymer.
In the insulated wires according to the second and third aspects of the present invention, the propylene-based copolymer preferably has a degree of crystallization of 38% to 60%.
In this case, as a result of the ratio of amorphous components susceptible to molecular vibration at high frequencies being further reduced in comparison with the case in which the degree of crystallization of the propylene-based copolymer is less than 38%, dielectric tangent can be more adequately lowered. In addition, if the degree of crystallization of the propylene-based copolymer is within the above-mentioned range, more suitable flexibility is obtained in comparison with the case of the degree of crystallization of the propylene-based copolymer exceeding 60%.
In the insulated wires according to the first to third aspects of the present invention, the conductor preferably has a body portion containing at least one type of material selected from the group consisting of copper, copper alloy, aluminum and aluminum alloy, and a plating film covering the body portion and containing at least one type of material selected, from the group consisting of tin and silver.
In this case, the body portion, which causes degradation of the base resin in the insulating layer, is covered with a plating film that contains at least one type of material selected from the group consisting of tin and silver. Consequently, degradation of the propylene-based copolymer attributable to the conductor is adequately inhibited even, if an antioxidant or metal deactivator is not contained in the insulating layer.
In the insulated wires according to the first to third aspects of the present invention, the above-mentioned insulating layer preferably has a thickness of 0.3 mm or less.
Propylene-based copolymers are typically brittle and tend to become even more brittle at lower temperatures normal temperature. Consequently, cracks and the like easily form in the insulating layer when the insulated wire is bent. In this point, if the thickness of the insulating layer is 0.3 mm or less, there is considerably less susceptibility to occurrence of the problem of embrittlement, and particularly low-temperature embrittlement, in comparison with the case of the thickness of the insulating layer exceeding 0.3 mm.
In addition, the insulated wires according to the first to third aspects of the present invention are preferably insulated wires used in a transmission cable.
In addition, a cable according to the first to third aspects of the present invention, is a cable having an insulated wire according to any of the above-mentioned first to third aspects.
Moreover, a transmission cable according to the first to third aspects of the present invention is a transmission cable having any of the above-mentioned insulated wires used in a transmission cable.
In the present invention, “melting point” refers to melting point as measured according to the method of JIS-K7121. More specifically, when a sample in an amount, of about 5 mg is used and the sample is:
1) held at a constant, temperature of 200° C. for 10 minutes;
2) lowered in temperature from 200° C. to −60° C. at the rate of 10° C./min;
3) held at a constant temperature of −60° C. for 10 minutes; and
4) raised in temperature from −60° C. to 200° C. at the rate of 10° C./min by DSC (Perkin-Elmer Diamond, input compensation type), the melting point refers to the heat-of-melting peak temperature determined as the peak of the heat of melting observed under the condition 4).
In addition, in the present invention, the contents of ethylene and butene in the propylene-based copolymer are determined by infrared spectroscopy in accordance with the calculation formulas described on pp. 413-415 of the Polymer Analysis Handbook of the Polymer Analysis Research Group, The Japan Society for Analytical Chemistry. More specifically, the ethylene and butene contents in the propylene-based copolymer are determined from absorbance obtained by measuring with an infrared spectrophotometer (PerkinElmer Co., Ltd., Spectrum One, FTIR) under conditions of a resolution of 2 cm−1 in the transmission mode at 64 cycles of integration using a test piece obtained by peeling off the insulating layer from an insulated wire and molding the insulating layer to a thickness of 0.5 mm to 1 mm with a hydraulic press. Here, ethylene refers to ethylene structural units in the propylene-based copolymer, and not to ethylene monomers. Similarly, butene refers to 1-butene structural units in the propylene-based copolymer, and not to butene monomers. Furthermore, the above-mentioned calculation formulas are represented by the following formulas (1) to (3). Here, Ak represents absorbance at k cm−1, t represents the thickness (cm) of the test piece, and ρ represents the density (g/cm3) of the test piece. In addition, “PP” represents the propylene-based copolymer.
Ethylene in random PP(% by mass)=(0.509A733+0.438A722)/tρ (1)
Ethylene in block PP(% by mass)=(1.10A722−1.51A729+0.509A733)/tρ (2)
1-butene(% by mass)=12.3(A766/t) (3)
Moreover, in the present invention, “crystallization peak temperature” refers to crystallization peak temperature determined from the peak of the heat of crystallization observed under the conditions described, in the above-mentioned 2).
Moreover, in the present invention, “degree of crystallization” is defined with the following formula:
Xc=Hm/H
m0
(wherein, Xc represents degree of crystallization (%), Hm represents heat of melting (J/g), and Hm0 represents heat of 100% crystallization (J/g). Here, Hm is the heat of melting at the peak of the heat of melting observed when measuring the melting point of the propylene-based copolymer as previously described, and the value determined according to the method of JIS-K7122 is used as the heat of melting. A value of 165 J/g is used for Hm0. Here, the value of Hm0 was excerpted from the Polypropylene Handbook, Edward P. Moore, Jr., ed. (1998, p. 149).
According to the first aspect of the present invention, an insulated wire and a cable are provided that have superior dielectric characteristics in the gigahertz band and are able to realize superior heat aging resistance characteristics.
In addition, according to the second and third aspects of the present invention, an insulated wire and a cable are provided that have superior dielectric characteristics in the gigahertz band and are able to realize superior crush resistance and heat resistance.
The following provides an explanation of the present invention.
<First Aspect>
The following provides a detailed explanation of the first aspect of the present invention using
Here, the insulating layer 2 contains as a base resin thereof a propylene-based copolymer obtained by synthesizing using a metallocene catalyst, and an antioxidant having a chemical structure that differs from a hindered phenol structure. Here, the antioxidant is incorporated at a ratio of not less than 0.01 parts by mass to less than 1.5 parts by mass based on 100 parts by mass of the propylene-based copolymer.
According to the cable 10, superior dielectric characteristics in the gigahertz band can be realized by using the insulated wire 5 that uses the insulating layer 2 having the above-mentioned configuration. The reason for being able to realize superior dielectric characteristics in the gigahertz band by the insulated wire 5 in this manner is thought by the inventor of the present invention to be as indicated below. Namely, since the propylene-based copolymer contained in the insulating layer 2 is obtained by synthesizing using a metallocene catalyst, the width of molecular weight distribution can be narrowed as compared with a propylene-based copolymer synthesized using a general-purpose catalyst such as a Ziegler-Natta catalyst. Consequently, the ratio of low molecular weight propylene-based copolymers in the insulating layer 2, which are thought to cause large increases in dielectric tangent resulting from increased susceptibility to molecular vibration at high frequencies in the gigahertz band, can be adequately reduced. Consequently, the inventor of the present invention considers that superior dielectric characteristics can be realized by the insulated wire 5 in the manner described above.
In addition, the propylene-based copolymer is typically susceptible to oxidative degradation due to contact with the internal conductor 1, and contains easily degradable tertiary carbons. Consequently, the molecules in propylene-based copolymers are easily severed. In this point, the insulating layer 2 contains an antioxidant having a chemical structure that differs from a hindered phenol structure, and this antioxidant is incorporated at a ratio of not less than 0.01 parts by mass to less than 1.5 parts by mass based on 100 parts by mass of the propylene-based copolymer. Consequently, degradation of the propylene-based copolymer caused by the internal conductor 1 can be adequately inhibited. Consequently, the insulated wire 5 has superior dielectric characteristics in the gigahertz band and is able to realize superior heat aging resistance characteristics.
Next, an explanation is provided of a production method of the cable 10.
First, an explanation is provided of a production method of the insulated wire 5.
<Internal Conductor>
First, the internal conductor is prepared. Examples of the internal conductor 1 include metal wires composed of a metal such as copper, copper alloy, aluminum or aluminum alloy. These metals can be each used alone or in combination. In addition, as shown, in
<Insulating Layer>
Next, the insulating layer 2 is formed on the internal conductor 1.
In order to form the insulating layer 2, a propylene-based copolymer as a base resin and an antioxidant are prepared.
(Base Resin)
The propylene-based copolymer is a propylene-based copolymer obtained by synthesizing using a metallocene catalyst. A propylene-based copolymer refers to a resin that contains propylene as a constituent, and includes not only homopolypropylene, but also copolymers of propylene and other olefins. Examples of other olefins include ethylene, 1-butene, 2-butene, 1-hexene and 2-hexene. Other olefins can be used alone or two or more types can be used in combination. Among these, ethylene or 1-butene is used preferably since it makes crystallinity low and is able to efficiently lower melting point while minimizing deterioration of various characteristics as much as possible when added in small amounts, and ethylene is used more preferably.
More specifically, examples of propylene-based copolymers include ethylene-propylene copolymers, ethylene-propylene-butene copolymers, propylene-butene copolymers, ethylene-propylene-butene-hexene copolymers, ethylene-propylene-hexene copolymers and propylene-butene-hexene copolymers.
Although the propylene-based copolymer may be a random copolymer or block copolymer, it is preferably a random copolymer. In this case, the melting point of the propylene-based copolymer can be further lowered and the flexibility of the insulated wire 5 can be further improved in comparison with the case in which the propylene-based copolymer is a block copolymer.
The melting point of the propylene-based copolymer is preferably 125° C to 145° C. If the melting point of the propylene-based copolymer is within the above-mentioned range, more adequate heat, resistance can be obtained in comparison with the case of the melting point being lower than 125° C. In addition, if the melting point of the propylene-based copolymer is within the above-mentioned range, superior dielectric characteristics can be obtained since the crystallinity of the propylene-based copolymer becomes higher. In addition, since crystallinity does not become excessively high in comparison with the case of the melting point of the propylene-based copolymer exceeding 145° C., flexibility required for use as a cable is obtained.
The melting point of the propylene-based copolymer is preferably 130° C. to 145° C. and more preferably 133° C. to 143° C.
The total content of ethylene and butene in the propylene-based copolymer is preferably 7% by mass or less, and the content of butene in the propylene-based copolymer preferably does not exceed 2% by mass.
The content of ethylene in the propylene-based copolymer is 5% by mass or less, preferably 4.5% by mass or less, and more preferably 3.0% by mass or less. However, from the viewpoint of improving flexibility, the content of ethylene in the propylene-based copolymer is preferably 1.0% by mass or more and more preferably 1.3% by mass or more. In addition, the content of butene in the propylene-based copolymer is within a range that does not exceed 2.0% by mass, and is preferably 1.5% by mass or less and more preferably 1.0% by mass or less. However, the content of butene is preferably 0.5% by mass or more from the viewpoint of improving flexibility, and in the case in which crystallinity is able to be efficiently lowered with ethylene alone, the propylene-based copolymer more preferably does not contain butene.
Furthermore, the contents of ethylene and butene in the propylene-based copolymer can be adjusted by, for example, mixing propylene-based copolymers synthesized using a metallocene catalyst.
The propylene-based copolymer preferably satisfies the following equation:
Melting point−crystallization peak temperature=30° C. to 40° C.
The difference between melting point and crystallization peak temperature is preferably 30° C. to 35° C. and more preferably 31° C. to 34° C.
Furthermore, the difference between melting point and crystallization peak temperature of the propylene-based copolymer can be adjusted by mixing propylene-based copolymers synthesized using a metallocene catalyst.
The propylene-based copolymer preferably has a degree of crystallization of 38% to 60%. If the degree of crystallization of the propylene-based copolymer is within the above-mentioned range, dielectric tangent can be more adequately lowered as a result of the ratio of amorphous components susceptible to molecular vibration at high frequency bands being further decreased in comparison with the case of the degree of crystallization being less than 38%. In addition, more suitable flexibility is obtained in comparison with the case of the degree of crystallization of the propylene-based copolymer exceeding 60%.
(Antioxidant)
The antioxidant prevents degradation of the base resin caused by contact with the internal conductor 1, and may be any antioxidant provided it has a chemical structure that differs from a hindered phenol structure.
Examples of antioxidants having a chemical structure that differs from a hindered phenol structure include semi-hindered phenol-based antioxidants and less-hindered phenol-based antioxidants.
Examples of semi-hindered phenol-based antioxidants include 3,9-bis[2-{3-(3-tertiary-butyl-4-hydroxy-5-methylphenyl)propionyloxy}-1,1-dimethylethyl]-2,4,8,10-tetraoxaspiro[5,5]undecane (for example, ADK STAB AO-80 manufactured by ADEKA CORPORATION), ethylenebis(oxyethylene)bis[3-(5-tert-butyl-hydroxy-m-tolyl)propionate] (for example, IRGANOX 245 manufactured by BASF SE), and triethylene glycolbis[3-(3-tert-butyl-4-hydroxy-5-methylphenyl)propionate] (for example, ADK STAB AO-70 manufactured by ADEKA CORPORATION).
Examples of less-hindered phenol-based antioxidants include 4,4′-thiobis(3-methyl-6-tertiary-butyl)phenol (for example, NOCRAC 300 manufactured by OUCHI SHINKO CHEMICAL INDUSTRIAL CO., LTD.), 1,1,3-tris-(2-methyl-4-hydroxy-5-tertiary-butylphenyl)butane (for example, ADK STAB AO-30 manufactured by ADEKA CORPORATION), and 4,4′-butylidenebis(3-methyl-6-tertiary-butyl)phenol (for example, ADK STAB AO-40 manufactured by ADEKA CORPORATION).
These antioxidants are able to further improve dielectric characteristics in the gigahertz band since they are comparatively insusceptible to frequency.
The antioxidant is added at a ratio of not less than 0.01 parts by mass to less than 1.5 parts by mass based on 100 parts by mass of the above-mentioned propylene-based copolymer. In this case, in addition, to allowing the obtaining of superior dielectric characteristics, the antioxidant is able to adequately inhibit so-called bloom phenomenon in which particles of antioxidant appear on the surface of the insulating layer 2 in comparison, with the case of incorporating at a ratio of 1.5 parts by mass or more. In addition, heat aging resistance is remarkably improved in comparison with the case of incorporating the antioxidant at a ratio of less than 0.01 parts by mass. The antioxidant is more preferably incorporated, at a ratio of 1 part by mass or less based on 100 parts by mass of the propylene-based copolymer. However, from the viewpoint of improving heat aging resistance with the antioxidant, it is preferably incorporated at a ratio of 0.05 parts by mass or more based on 100 parts by mass of the base resin.
The above-mentioned insulating layer 2 is obtained by loading the base resin in the form of the propylene-based copolymer, the antioxidant, and as necessary, a metal deactivator into an extruder, melting, kneading and extruding the resin composition in the extruder, and covering the internal conductor 1 with this extrudate.
The outer diameter of the insulating layer 2 is preferably 40 mm or less, more preferably 8 mm or less and particularly preferably 1 mm or less.
Moreover, as shown in
However, the thickness t of the insulating layer 2 may also be greater than 0.3 mm. In this case as well, the problem of low-temperature embrittlement is less likely to occur if used in applications in which the cable 10 is hardly subjected to any bending. However, the thickness t of the insulating layer 2 is normally 6 mm or less for reasons that it is not preferable that workability (weight) at the time of laying cables become poor and the amount of copper used increase unnecessarily.
In the insulated wire 5, although the insulating layer 2 may be a non-foamed body or foamed body, it is preferably a non-foamed body. Production is easier in the case in which the insulating layer 2 is a non-foamed body in comparison with the case of being a foamed body. Consequently, there is less susceptibility to the occurrence of deterioration of skew, deterioration of VSWR and accompanying increases in attenuation caused by changes in outer diameter of the insulating layer 2 and the like. This becomes particularly prominent as the outer diameter of the insulating layer 2 becomes smaller, and more specifically, when the outer diameter of the insulating layer 2 becomes 0.7 mm or less. Furthermore, in the case in which the insulating layer 2 is a foamed, body, the degree of foaming is preferably 30% to 60%. Here, the degree of foaming is calculated based on the equation indicated below,
Degree of foaming(%)=[1−(specific gravity of foamed insulating layer after foaming/specific gravity of resin before foaming)]×100 [Math. 1]
In this case, increased coarseness of foam cells can be inhibited even when a wire using a propylene-based copolymer for the insulating layer 2 is used as a cable used in the gigahertz band, and a foamed insulating layer 2 can be obtained that has fine, uniform, foam cells. In addition, the cable 10 that uses the insulated wire 5 has small variations in outer diameter, has few problems caused by crushing even if the thickness of the insulating layer 2 is reduced, and enables variations such as degradation of attenuation to be adequately inhibited.
In the case in which the insulating layer 2 is a foamed insulating layer, the foamed insulating layer can be obtained by incorporating a foaming agent such as a chemical foaming agent in the resin composition.
In addition, a thin layer composed, of an unfoamed resin in the form of a so-called inner layer is preferably interposed between the insulating layer 2 and the internal conductor 1. As a result thereof, adhesion between the insulating layer 2 and the internal conductor 1 can be improved. In the case in which the unfoamed resin is composed of polyethylene in particular, adhesion between the insulating layer 2 and the internal conductor 1 can be further improved. In addition, the above-mentioned inner layer can also prevent degradation (embrittlement) of the insulating layer 2 caused by copper in the internal conductor 1. Furthermore, the thickness of the inner layer is, for example, 0.01 mm to 0.1 mm.
Moreover, a thin layer in the form of a so-called outer layer is preferably interposed between the insulating layer 2 and the outer conductor 3. There are many cases in which a transmission cable is required to be colored. In such cases, the use of an unfoamed resin as a thin layer enables coloring to be easily carried out without deteriorating electrical characteristics in comparison with the case of coloring with a pigment. In addition, if a thin layer composed of a foamed resin is interposed between the insulating layer 2 and the external conductor 3, the appearance of the insulated wire 5 is improved. Moreover, variations in outer diameter of the insulated wire 5 become small, skew and VSWR improve, crush resistance improves, and the outer diameter of the insulated wire 5 can be reduced. Furthermore, the thickness of the outer layer is, for example, 0.02 mm to 0.2 mm.
Moreover, the insulating layer 2 may be a layer obtained by melting and kneading the resin composition, and extruding and covering the internal conductor 1 followed by crosslinking the extrudate. In this case, although crosslinking treatment can be carried out by, for example, electron beam irradiation, in the case in which the resin composition contains a crosslinking agent such as an organic peroxide or sulfur, crosslinking treatment can also be carried out by heating. However, crosslinking treatment is preferably carried out by electron beam irradiation from the viewpoint of improving electrical characteristics.
<External Conductor>
Next, the external conductor 3 is formed so as to surround the insulated wire 5 obtained in the manner described above. A known external conductor used in the prior art can be used for the external conductor 3. For example, the external conductor 3 can be formed by wrapping a conductive wire, or a tape composed by interposing an electrically conductive sheet between resin sheets around the outer periphery of the insulating layer 2. In addition, the external conductor 3 can also be composed of a metal tube subjected to corrugation processing, namely molded to have a corrugated shape.
<Sheath>
Finally, the sheath 4 is formed. The sheath 4 protects the external conductor 3 from physical or chemical damage, and although examples of materials that compose the sheath 4 include resins such as fluororesin, polyethylene or polyvinyl chloride, from the viewpoints of environmental considerations and the like, a halogen-free material such as polyethylene resin is used preferably.
The cable 10 is obtained in the manner described above.
<Second Aspect>
Next, an explanation is provided of the second aspect of the present invention.
A cable of the present aspect differs from the cable of the first aspect in that the insulating layer 2 is composed in the manner described below. Namely, in the present aspect, the insulating layer 2 contains as a base resin thereof a propylene-based copolymer having a melting point of 125° C. to 145° C. Here, the total content of ethylene and butene in the propylene-based copolymer is 7% by mass or less, and the content of butene in the propylene-based copolymer does not exceed 2% by mass.
According to the cable 10 having this type of configuration, superior dielectric characteristics in the gigahertz band can be realized by using the insulated wire 5 that uses the insulating layer 2 having the above-mentioned configuration. The reason for being able to realize superior dielectric characteristics in the gigahertz band by the insulated wire 5 in this manner is thought by the inventor of the present invention to be as indicated below. Namely, since ethylene and butene in the propylene-based copolymer inhibit crystallization of propylene, an amorphous portion is formed easily. This amorphous portion is thought to be susceptible to the occurrence of molecular vibration at high-frequency bands and be susceptible to the occurrence of heat loss. Consequently, the inventor of the present invention considered that, if the total content of ethylene and butene becomes high and the content of butene is higher than 2% by mass, dielectric tangent may increase easily attributable to the ethylene and butene. Therefore, by making the total content of ethylene and butene to be 7% by mass or less and the content of butene to not exceed 2% by mass as previously described, a melting point of 125° C. or higher can be imparted to the propylene-based copolymer, and deterioration of dielectric tangent attributable to ethylene and butene can be reduced.
In addition, the propylene-based copolymer has a melting point of 125° C. to 145° C. Consequently, adequate mechanical strength can be imparted to the insulating layer 2, and superior crush resistance can be imparted to the insulating layer 2. Consequently, the propylene-based copolymer also has superior heat resistance at the level of UL90° C.
(Base Resin)
The propylene-based copolymer refers to a copolymer of propylene and other olefins, and examples of other olefins include ethylene, 1-butene, 2-butene, 1-hexene and 2-hexene. Other olefins can be used alone or two or more types can be used in combination. Among these, ethylene or 1-butene is used preferably since it lowers crystallinity of the propylene-based copolymer and is able to efficiently lower melting point while minimizing deterioration of various characteristics as much as possible when added in small amounts, and ethylene is used more preferably.
More specifically, examples of propylene-based copolymers include ethylene-propylene copolymers, ethylene-propylene-butene copolymers, propylene-butene copolymers, ethylene-propylene-butene-hexene copolymers, ethylene-propylene-hexene copolymers and propylene-butene-hexene copolymers.
The propylene-based copolymer is preferably obtained by synthesizing using a metallocene catalyst.
In this case, the width of molecular weight distribution of the propylene-based copolymer can be narrowed as compared with a propylene-based copolymer synthesized using a general-purpose catalyst such as a Ziegler-Natta catalyst. As a result, the ratio of low molecular weight components susceptible to the occurrence of molecular vibration at high-frequency bands can be further reduced, and increases in dielectric tangent caused by low molecular weight components can be adequately inhibited. In addition, if the propylene-based copolymer is obtained by synthesizing using a metallocene catalyst, the contents of ethylene and butene in a propylene-based copolymer having a desired melting point can be efficiently reduced.
Although the propylene-based copolymer may be a random copolymer or block copolymer, it is preferably a random copolymer. In this case, the melting point of the propylene-based copolymer can be further lowered and the flexibility of the insulated wire 5 can be further improved in comparison with the case in which the propylene-based copolymer is a block copolymer.
The melting point of the propylene-based copolymer is 125° C. to 145° C. If the melting point is lower than 125° C., adequate heat resistance cannot be obtained, while if the melting point exceeds 145° C., flexibility required for use as a cable is inadequate since the crystallinity of the propylene-based copolymer becomes excessively nigh.
The melting point of the propylene-based copolymer is preferably 130° C. to 145° C. and more preferably 133° C. to 143° C.
The content of ethylene in the propylene-based copolymer is normally 5% by mass or less, preferably 4.5% by mass or less, and more preferably 3.0% by mass or less. However, from the viewpoint of improving flexibility, the content of ethylene in the propylene-based copolymer is preferably 1.0% by mass or more and more preferably 1.3% by mass or more. In addition, the content of butene in the propylene-based copolymer is within a range that does not exceed 2.0% by mass, and is preferably 1.5% by mass or less and more preferably 1.0% by mass or less. However, although the content of butene is preferably 0.5% by mass or more from the viewpoint of improving flexibility, in the case in which crystallinity is able to be efficiently lowered with ethylene alone, the propylene-based copolymer more preferably does not contain butene.
Furthermore, although the contents of ethylene and butene in the propylene-based copolymer can be adjusted by mixing propylene-based copolymers synthesized using a metallocene catalyst, the contents can also be adjusted by mixing a propylene-based copolymer synthesized using a metallocene catalyst and a propylene-based copolymer synthesized using a general-purpose catalyst such as a Ziegler-Natta catalyst.
The propylene-based copolymer preferably has a degree of crystallization of 38% to 60%. In this case, if the degree of crystallization of the propylene-based copolymer is within the above-mentioned range, as a result of the ratio of the amorphous portion susceptible to the occurrence of molecular vibration at high-frequency bands being further reduced in comparison, with the case of the degree of crystallization being less than 38%, dielectric tangent can be more adequately lowered. In addition, more suitable flexibility can be obtained, in comparison with the case of the degree of crystallization of the propylene-based copolymer exceeding 60%. Moreover, the propylene-based copolymer more preferably has a degree of crystallization of 50% to 60%.
At least one of a metal deactivator and antioxidant may also be added to the propylene-based copolymer as necessary,
(Metal Deactivator)
The metal deactivator may be any metal deactivator provided it prevents degradation of the base resin caused by contact with the internal conductor 1. This metal deactivator is preferably a hydrazide-based metal deactivator having a chemical structure that differs from a hindered phenol. 3-(N-salicyloyl)amino-1,2,4-triazole (for example, CDA-1 manufactured by ADEKA CORPORATION or CDA-1M manufactured by ADEKA CORPORATION), 2′,3-bis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionyl]propionohydrazide, or decamethylene dicarboxylic acid disalicyloyl hydrazide (for example, CDA-6 manufactured by ADEKA CORPORATION) is used for this type of metal deactivator. These can be used alone or two or more types can be used as a mixture. In particular, 3-(N-salicyloyl)amino-1,2,4-triazole and 2′,3-bis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionyl]propionohydrazide are preferable since they enable more effective improvement of heat aging resistance characteristics.
The metal deactivator is preferably incorporated at a ratio of less than 1.5 parts by mass based on 100 parts by mass of the base resin. In this case, so-called bloom phenomenon in which particles of metal deactivator appear on the surface of the insulating layer 2 can be adequately inhibited in comparison with the case of incorporating the metal deactivator at a ratio of 1.5 parts by mass or more. The metal deactivator is more preferably incorporated at a ratio of 1 part by mass or less based on 100 parts by mass of the base resin. However, it is preferably incorporated at a ratio of 0.01 parts by mass or more based on 100 parts by mass of the base resin from the viewpoint of further improving heat aging resistance characteristics by the metal deactivator,
(Antioxidant)
The antioxidant may be any antioxidant provided it prevents degradation of the base resin due to contact with the internal conductor 1.
Examples of antioxidants include monophenol-based compounds such as 2,6-di-tert-butylphenol, 2,6-di-tert-butyl-4-ethylphenol, 2,6-di-tert-butyl-4-methylphenol, 2,6-di-tert-butyl-α-dimethylamino-p-cresol, 2,4,6-tri-tert-butylphenol or o-tert-butylphenol, polyphenol-based compounds such as 2,2′-methylene-bis-(4-methyl-6-tert-butylphenol), 2,2′-methylene-bis-(4-ethyl-6-tert-butylphenol), 4,4′-methylene-bis-(2,6-di-tert-butylphenol), 4,4′-butylidene-bis-(4-methyl-6-tert-butylphenol), alkylated bisphenol or 1,3,5-trimethyl-2,4,6-tris(3,5-di-tert-butyl-4-hydroxybenzy)benzene, hindered phenol-based compounds such as tetrakis-[methylene-3-(3′,5′-di-tert-butyl-4′-hydroxyphenyl)propionate]methane, n-octadecyl-3-(4′-hydroxy-3′,5′-di-tert-butylphenyl)propionate, 1,1,3-tris(2-methyl-4-hydroxy-5-tert-butylphenyl)butane or 3,9-bis[2-{3-(3-tert-butyl-4-hydroxy-5-methylphenyl)propionyloxy}-1,1-dimethylethyl]-2,4,8,10-tetraoxaspiro[5,5]-undecane, thiobisphenol-based compounds such as 4,4′-thiobis-(6-tert-butyl-3-methylphenol), 4,4′-thiobis-(6-tert-butyl-o-cresol), bis(3,5-di-tert-butyl-4-hydroxybenzyl)sulfide or dialkyl phenol sulfide, phosphites, phosphorous-based tris(nonylphenyl) compounds such as tris(2,4-di-tert-butylphenyl)phosphite, dilauryl thiodipropionate, distearyl thiodipropionate, distearyl-β,β-thiodibutyrate, lauryl stearyl thiodipropionate, dimyristyl-3,3′-thiodipropionate, ditridecyl-3,3′-thiodipropionate, sulfur-containing ester-based compounds, amyl thioglycolate, 1,1′-thiobis-(2-naphthol), 2-mercaptobenzimidazole, hydrazine derivatives and phenol-based antioxidants having a chemical structure that differs from a hindered phenol structure. These antioxidants can be used alone or two or more types can be used in combination.
Examples of phenol-based antioxidants having a chemical structure that differs from a hindered phenol structure include the same semi-hindered phenol-based antioxidants and less-hindered phenol-based antioxidants as those of the first aspect. These antioxidants are comparatively insusceptible to frequency, and are able to further improve dielectric characteristics of the insulated wire 5 in the gigahertz band.
The antioxidant is preferably incorporated at a ratio of less than 1.5 parts by mass based on 100 parts by mass of the above-mentioned base resin. In this case, so-called bloom phenomenon in which particles of antioxidant appear on the surface of the insulating layer 2 can be adequately inhibited in comparison with the case of incorporating the antioxidant at a ratio of 1.5 parts by mass or more. The antioxidant is more preferably incorporated at a ratio of 1 part by mass or less based on 100 parts by mass of the base resin. However, from the viewpoint of further improving heat aging resistance characteristics with the antioxidant, the antioxidant is preferably incorporated at a ratio of 0.01 parts by mass or more based on 100 parts by mass of the base resin.
Furthermore, the ratio at which the antioxidant is incorporated may also be zero from the viewpoints of realizing superior dielectric characteristics as well as crush resistance and heat resistance.
Furthermore, in the cable of the present aspect, in the case in which the internal conductor 1 has the body portion 1a containing at least one type selected from the group consisting of copper, copper alloy, aluminum and aluminum alloy, and the plating film 1b that covers the body portion 1a and contains at least one type selected from the group consisting of tin and silver as shown in
The above-mentioned insulating layer 2 is obtained by loading the above-mentioned base resin and., as necessary, the metal deactivator and antioxidant into an extruder, melting, kneading and extruding the resin composition in the extruder, and covering the internal conductor 1 with this extrudate.
<Third Aspect>
Next, an explanation is provided of the third aspect of the present invention. The cable of the present aspect differs from the cable of the second aspect, which is provided with the insulating layer 2 in which the total content of ethylene and butene in the propylene-based copolymer is 7% by mass or less and the content of butene in the propylene-based copolymer does not exceed 2% by mass, in that the propylene-based copolymer contained in the insulating layer 2 satisfies the equation indicated below:
melting point−crystallization peak temperature=30° C. to 40° C.
According to this cable 10 having such a configuration, superior dielectric characteristics in the gigahertz band can be realized by using the insulated wire 5 that uses the insulating layer 2 having the above-mentioned configuration. The reason for being able to realize superior dielectric characteristics in the gigahertz band by the insulated wire 5 in this manner is thought by the inventor of the present invention to be as indicated below. Namely, if the amount of low molecular weight components is large, melting point and crystallization temperature become lower as a result of being influenced by these low molecular weight components. Thus, in the case of the same melting point, the crystallization peak temperature becomes lower the greater the amount of low molecular weight components, and the difference between the peak temperature of the melting point (melting point) and the crystallization peak temperature, namely the peak temperature difference, becomes larger. A small peak temperature difference indicates a narrow molecular weight distribution, and if the molecular weight distribution is narrow, there is less susceptibility to the occurrence of heat loss caused by molecular vibration attributable to low molecular weight components. Thus, superior dielectric characteristics are thought to be obtained. Therefore, dielectric tangent can be lowered by making the difference between melting point and crystallization peak temperature to be 30° C. to 40° C. as previously described.
The difference between melting point and crystallization peak temperature in the propylene-based copolymer is preferably 30° C. to 35° C. and more preferably 31° C. to 34° C.
Furthermore, although the value of the difference between melting point and crystallization peak temperature of the propylene-based copolymer can be adjusted by mixing propylene-based copolymers synthesized using a metallocene catalyst, it can also be adjusted by mixing a propylene-based copolymer synthesized using a metallocene catalyst and a propylene-based copolymer synthesized using a general-purpose catalyst such as a Ziegler-Natta catalyst.
The present invention is not limited to the above-mentioned first to third aspects. For example, although examples of applying the insulated wire 5 to a cable such as a coaxial cable or twinax cable are indicated in the above-mentioned first to third aspects, the insulated wire 5 can also be applied to a high-speed transmission cable such as a USB 3.0 cable, HDMI cable, InfiniBand cable or micro USB cable.
Although the following provides a more specific explanation of the contents of the present invention by indicating examples and comparative examples, the present invention is not limited to the following examples.
First, an ethylene-propylene random copolymer in the form of WMG03 (melting point: 142° C.), obtained by synthesizing using a metallocene catalyst, was prepared for use as a base resin.
The above-mentioned base resin and the antioxidant and metal deactivator shown in Table 1 were loaded into an extruder (product name: LABOPLASTOMILL 4C150, twin-screw segmented extruder 2D30W2, screw diameter (D): 25 mm, effective screw length (L): 750 mm, manufactured by Toyo Seiki Seisaku-Sho, Ltd.) followed by melting and kneading to obtain a molten mixture. At this time, the incorporated amounts of antioxidant and metal deactivator shown in Table 1 were the amounts incorporated based on 100 parts by mass of the base resin (units: parts by mass), and the melting and kneading temperature was 200° C.
The above-mentioned molten extrudate was further melted and kneaded with an extruder (screw diameter (D): 25 mm, effective screw length (L): 800 mm, manufactured by Hijiri Manufacturing Ltd.) set to a temperature of 200°C. and extruded into the shape of a tube. A tin-plated copper wire having a diameter of 0.172 mm was then covered with this tubular extrudate. Thus, an insulated wire was fabricated that was composed of a conductor and an insulating layer covering the conductor. At this time, the extrudate was extruded so that the outer diameter of the insulating layer was 0.6 mm and the thickness was 0.215 mm.
The insulated wire obtained in this manner was then wrapped with a laminate tape having a thickness of 25 μm and composed of a laminate of an aluminum layer and a polyethylene terephthalate layer. Next, this was covered with a sheath composed of PVC (polyvinyl chloride) having a thickness of 0.4 mm. Thus, a non-foamed and non-crosslinked coaxial cable was fabricated having impedance of 50Ω.
Coaxial cables were fabricated in the same manner as Example 1 with the exception of incorporating the antioxidants and metal deactivators shown in Table 1 at the ratios shown in Table 1 (units: parts by mass) based on 100 parts by mass of the base resins shown in Table 1.
The base resins shown in Table 1 were loaded into an extruder set to a temperature of 200° C. (screw diameter (D): 25 mm, effective screw length (L): 800 mm, manufactured by Hijiri Manufacturing Ltd.), melted, kneaded and extruded into the shape of a tube. A tin-plated copper wire having a diameter of 0.172 mm was then covered with this tubular extrudate. Thus, insulated wires were fabricated that were composed of a conductor and an insulating layer covering the conductor. At this time, the extrudate was extruded so that the outer diameter of the insulating layer was 0.6 mm and the thickness was 0.215 mm.
Coaxial cables were then fabricated in the same manner as Example 1 using the insulated wires obtained in this manner.
Coaxial cables were fabricated in the same manner as Example 1 with the exception of setting the thickness of the insulating layer to values as shown in Table 3.
Furthermore, the products indicated below were specifically used for the base resins, antioxidants and metal deactivators shown in Table 1.
(1) Base Resins
(1-1) WFX4 (WINTEC, Manufactured by Japan Polypropylene Corporation)
(1-2) WFW4 (WINTEC, Manufactured by Japan Polypropylene Corporation)
(1-3) WMG03 (WINTEC, Manufactured by Japan Polypropylene Corporation)
(1-4) WFX6 (WINTEC, Manufactured by Japan Polypropylene Corporation)
(1-5) FX4G (NOVATEC-PP, Manufactured by Japan Polypropylene Corporation)
(1-6) FW4B (NOVATEC-PP, Manufactured by Japan Polypropylene Corporation)
(2) Antioxidants
(2-1) Semi-Hindered Phenol-Based Antioxidants
(2-2) Less-Hindered Phenol-Based Antioxidants
(2-3) Hindered Phenol-Based Antioxidants
(3) Metal Deactivators
(3-1) Non-Hindered Phenol-Based Metal Deactivators
(3-2) Hindered Phenol-Based Metal Deactivators
[Characteristics Evaluation]
The following characteristics were evaluated for the coaxial cables obtained in Examples 1 to 27 and Comparative Examples 1 to 9.
(1) Ethylene and Butene Contents
Ethylene content and butene content were calculated from IR spectra measured for test pieces composed of an insulating layer obtained by peeling off the insulating layer of insulated wires of the coaxial cables of Examples 1 to 22 and Comparative Examples 1 to 9. The results are shown in Table 1.
(2) Crystallization Peak Temperature, Melting Heat Peak Temperature (Melting Point) and Degree of Crystallization
Crystallization peak temperature and melting heat peak temperature were calculated by measuring by DSC for test pieces composed of an insulating layer obtained by peeling off the insulating layer of insulated wires of the coaxial cables of Examples 1 to 22 and Comparative Examples 1 to 9. The results are shown in Table 1. In addition, degree of crystallization was also calculated by measuring by DSC for the same test pieces. The results are shown in Table 1.
(3) Dielectric Characteristics (tan δ)
Dielectric characteristics were investigated by measuring dielectric tangent (tan δ). Here, dielectric tangent (tan δ) was respectively measured at measuring frequencies of 3.0 GHz, 6.9 GHz, 10.7 GHz and 14.6 GHz with a microwave measuring system using the SUM-TM0m0 measurement program available from SUMTEC, Inc. for a sheet obtained by molding resin compositions used to produce the insulating layers of the coaxial cables of Examples 1 to 22 and Comparative Examples 1 to 9 into the shape of rods having a diameter of 2 mm and length of 10 cm. The results are shown in Table 2. Acceptance criteria for tan δ at each frequency were as indicated below.
3.0 GHz: 1.10×10−4 or less
6.9 GHz: 1.50×10−4 or less
10.7 GHz: 2.00×10−4 or less
14.6 GHz: 2.50×10−4 or less
(4) Attenuation
Attenuation was respectively measured at frequencies of 3.0 GHz, 6.9 GHz, 10.7 GHz and 14.6 GHz using a network analyzer (8722ES, manufactured by Agilent Technologies, Inc.) for the coaxial cables obtained in Examples 1 to 22 and Comparative Examples 1 to 9. The results are shown in Table 2.
(5) Heat Resistance
Test pieces were fabricated by cutting the insulated wires of the coaxial cables of Examples 1 to 22 and Comparative Examples 1 to 9 to a length of 30 mm. The test pieces were placed in the center of a sample stand having a diameter of 9 mm followed by measurement of the amount of deformation under a load of 250 g, load duration of 1 hour and temperature of 121° C. using a heat deformation tester (Triple Parallel Plate Plastomer Model W-3, manufactured by Toyo Seiki Seisaku-sho, Ltd.). Crushing ratio (heat deformation ratio) was calculated, from the amount of deformation, and this crushing ratio was used as an indicator of neat resistance. The results are shown in Table 2.
(6) Crush Resistance
Shore D hardness, which indicates surface hardness, was measured and this Shore D hardness was used as an indicator of crush resistance. The Shore D hardness of the insulated wires of Examples 1 to 22 and Comparative Examples 1 to 9 was measured in compliance with JIS K7215. Results measured at a load holding time of 5 seconds are shown in Table 2.
(7) Heat Aging Resistance Characteristics
Heat aging resistance characteristics were evaluated in the manner described below. Namely, tensile strength, and elongation, retention were first measured by carrying out tensile tests on the coaxial cables of Examples 1 to 22 and Comparative Examples 1 to 9. These were referred, to as “initial tensile strength” and “initial elongation retention”, respectively. Next, tensile strength and elongation retention were measured by carrying out tensile tests after allowing the coaxial cables to stand in a constant temperature bath at 110° C. and periodically removing from the constant temperature bath. The number of days at which this tensile strength reached 50% of the initial tensile strength or the number of clays at which this elongation retention reached 50% of the initial elongation retention was calculated as a relative value in the case that the number of days for Comparative Example 6 in which antioxidant and metal deactivator were not used was set to a value of 100. The results are shown in Table 2. A relative value of 110 or more was judged to be “acceptable” in terms of having superior heat aging resistance, while a relative value of less than 110 was judged to be “unacceptable” in terms of having inferior heat aging resistance.
(8) Bloom (Blooming)
The sheath and laminate tape were removed from the coaxial cables of Examples 1 to 22 and Comparative Examples 1 to 9 cut to a length of 3 m, and the exposed surface of the insulating layer was observed visually after leaving for 3 months at 50° C. Bloom was evaluated based on the criteria indicated below. The results are shown in Table 2.
(9) Low-Temperature Embrittlement Characteristics
Low-temperature embrittlement characteristics were evaluated by carrying out a low-temperature embrittlement test on the coaxial cables of Examples 1 and 23 to 27. The low-temperature embrittlement test was carried, out in the manner indicated below.
Namely, embrittlement temperature was measured for the coaxial cables of Examples 1 and 23 to 27 using an embrittlement temperature tester (product name: Brittleness Tester TM-2110, manufactured by Ueshima Seisakusho Co., Ltd.). At this time, coaxial cables (samples) cut to about 60 mm were used as test pieces. Test conditions were in accordance with ASTM D746. In addition, the temperature at which damage or cracks occurred in the insulating layer was taken to be the embrittlement temperature (F50). The relationship between thickness of the insulating layer and embrittlement temperature was then investigated. The results are shown in Table 3.
According to the results shown in Tables 1 and 2, in each of Examples 1 to 22, dielectric tangent was low, attenuation was low, and the relative number of years representing heat aging resistance was high. In contrast, in Comparative Examples 1 to 9, it was found that the relative number of years representing heat aging resistance was low or that dielectric tangent was high.
Furthermore, according to the results shown in Table 3, it was also confirmed that embrittlement temperature decreased remarkably and low-temperature embrittlement characteristics improved remarkably by reducing the thickness of the insulating layer to 0.3 mm or less.
On the basis of the above, according to the insulated wire corresponding to the first aspect of the present invention, superior dielectric characteristics in the gigahertz band as well as superior neat aging resistance were confirmed to be able to be realized.
First, an ethylene-propylene random copolymer in the form of WMG03 (melting point: 142° C.), obtained by synthesizing using a metallocene catalyst, was prepared for use as a base resin.
The above-mentioned base resin was loaded into an extruder (screw diameter (D): 25 mm, effective screw length (L): 800 mm, manufactured by Hijiri Manufacturing Ltd.) followed by setting the temperature of the extruder to 200° C., melting, kneading and extruding into the shape of a tube. A tin-plated copper wire having a diameter of 0.172 mm was then covered with this tubular extrudate. Thus, an insulated wire was fabricated that was composed of a conductor and an insulating layer covering the conductor. At this time, the extrudate was extruded so that the outer diameter of the insulating layer was 0.6 mm and the thickness was 0.215 mm.
The insulated wire obtained in this manner was then wrapped with laminate tape having a thickness of 25 μm and composed of a laminate of an aluminum layer and a polyethylene terephthalate layer. Next, this was covered with a sheath composed of PVC (polyvinyl chloride) having a thickness of 0.4 mm. Thus, a non-foamed and non-crosslinked coaxial cable having impedance of 50Ω was fabricated.
Coaxial cables were fabricated in the same manner as Example 28 with the exception of using the base resins shown in Table 4.
Molten mixtures were obtained by loading the base resins, antioxidant and metal deactivator shown in Table 4 into an extruder (product name: LABOPLASTOMILL 4C150, twin-screw segmented extruder 2D30W2, screw diameter (D): 25 mm, effective screw length (L): 750 mm, manufactured by Toyo Seiki Seisaku-Sho, Ltd.) in the incorporated amounts shown in Table 4 (units: parts by mass) followed by melting and kneading. At this time, the melting and kneading temperature was 200° C.
The above-mentioned molten mixtures were further melted and kneaded with an extruder (screw diameter (D): 25 mm, effective screw length (L): 800 mm, manufactured by Hijiri Manufacturing Ltd.) set to a temperature of 200° C. and extruded into the shape of a tube. Tin-plated copper wires having a diameter of 0.172 mm were then covered with these tubular extrudates. Thus, insulated wires were fabricated that were composed of a conductor and an insulating layer covering the conductor. At this time, the extrudates were extruded so that the outer diameter of the insulating layer was 0.6 mm and the thickness was 0.215 mm.
Coaxial cables were then fabricated in the same manner as Example 28 using the insulated wires obtained in this manner.
Furthermore, the products indicated below were specifically used for the base resins, antioxidant and metal deactivator shown in Table 4.
(1) Base Resins
(1-1) WFX4 (WINTEC, Manufactured by Japan Polypropylene Corporation)
(1-2) WFW4 (WINTEC, Manufactured by Japan Polypropylene Corporation)
(1-3) WMG03 (WINTEC, Manufactured by Japan Polypropylene Corporation)
(1-4) FX4G (NOVATEC-PP, manufactured by Japan Polypropylene Corporation)
(1-5) FW4B (NOVATEC-PP, manufactured by Japan Polypropylene Corporation)
(2) Antioxidant
(2-1) ADK STAB AO-80, manufactured by ADEKA CORPORATION
(3) Metal Deactivator
(3-1) ADK STAB CDA-1, manufactured by ADEKA CORPORATION
Furthermore, in Table 4, the propylene-based copolymer of Examples 31 and 32 indicates a mixture of WFX4 and FX4G, the propylene-based copolymer of Examples 33 and 34 indicates a mixture of WFW4 and FW4B, and values shown, in parentheses indicate the mass ratios of WFX4, FX4G, WFW4 or FW4B based on 100 parts by mass for the total weight of the propylene-based copolymer.
[Characteristics Evaluation]
The following characteristics were evaluated for the coaxial cables obtained in Examples 28 to 37 and Comparative Examples 10 to 13.
(1) Ethylene and Butene Contents and Degree of Crystallization
Ethylene content and butene content were calculated, in the same manner as Example 1. The results are shown in Table 4. In addition, degree of crystallization was also calculated in the same manner as Example 1. The results are shown in Table 4.
(2) Dielectric Characteristics (tan δ)
Dielectric characteristics were respectively measured at measuring frequencies of 3.0 GHz, 6.9 GHz, 10.7 GHz and 14.6 GHz in the same manner as Example 1. The results are shown in Table 5. Acceptance criteria for tan δ at each frequency were the same as the criteria applied in Examples 1 to 27 and Comparative Examples 1 to 9.
(3) Attenuation
Attenuation was measured in the same manner as Example 1 for the coaxial cables obtained in Examples 28 to 37 and Comparative Examples 10 to 13. The results are shown in Table 5.
(4) Heat Resistance
Crushing ratio was calculated in the same manner as Example 1 for the coaxial cables of Examples 28 to 37 and Comparative Examples 10 to 13, and the resulting crushing ratios were used as an indicator of heat resistance. The results are shown in Table 5. Furthermore, a crushing ratio of less than 50% was judged to be acceptable in terms of having superior heat resistance, while a crushing ratio of 50% or more was judged to be unacceptable in terms of having inferior heat resistance.
(5) Crush Resistance
Shore D hardness, which indicates surface hardness, was measured and this Shore D hardness was used as an indicator of crush resistance. The Shore D hardness of the insulated wires of Examples 28 to 37 and Comparative Examples 10 to 13 was measured in the same manner as Example 1. Results measured at a load holding time of 5 seconds are shown in Table 5. Crush resistance was judged to be acceptable in terms of superior crush resistance if the Shore D hardness was 63 or more, and judged to be unacceptable in terms of inferior crush resistance if the Shore D hardness was less than 63.
(6) Heat Aging Resistance Characteristics
Heat aging resistance characteristics were evaluated in the same manner as Example 1. Namely, tensile tests were carried out on the coaxial cables obtained in Examples 28 to 37 and Comparative Examples 10 to 13, and the number of days at which the measured tensile strength reached 50% of the initial tensile strength or the number of days at which the measured elongation retention reached 50% of the initial elongation retention was calculated as a relative value in the case that the number of days for Example 28 in which antioxidant and metal deactivator were not used was set to a value of 100. The results are shown in Table 5. A relative value of 86 or more was judged to be “acceptable”, while a relative value of less than 86 was judged to be “unacceptable”.
(7) Bloom (Blooming)
Bloom was evaluated in the same manner as Example 1. The results are shown in Table 5. Furthermore, the criteria used to evaluate bloom were the same as the criteria applied in Examples 1 to 27 and Comparative Examples 1 to 9.
According to the results shown in Table 5, each of Examples 28 to 37 demonstrated low dielectric tangent, high Shore D hardness, and adequate heat resistance at the level of UL90° C., and satisfied acceptance criteria for all of dielectric characteristics, crush resistance and heat resistance. In contrast, Comparative Examples 10 to 13 did not satisfy acceptance criteria for at least one of dielectric characteristics, crush resistance and heat resistance.
Accordingly, according to the insulated wire corresponding to the second, aspect, of the present, invention, superior dielectric characteristics in the gigahertz band as well as superior crush resistance and heat resistance were confirmed to be able to be realized,
First, an ethylene-propylene random copolymer in the form of WMG03 (melting point: 142° C.), obtained by synthesizing using a metallocene catalyst, was prepared for use as a base resin.
The above-mentioned base resin was loaded into an extruder (screw diameter (D): 25 mm, effective screw length (L): 800 mm, manufactured by Hijiri Manufacturing Ltd.) followed by setting the temperature of the extruder to 200° C., melting, kneading and extruding into the shape of a tube. A tin-plated copper wire having a diameter of 0.172 mm was then covered with this tubular extrudate. Thus, an insulated wire was fabricated that was composed of a conductor and an insulating layer covering the conductor. At this time, the extrudate was extruded so that the outer diameter of the insulating layer was 0.6 mm and the thickness was 0.215 mm.
The insulated wire obtained in this manner was then wrapped with laminate tape having a thickness of 25 μm and composed of a laminate of an aluminum layer and a polyethylene terephthalate layer. Next, this was covered with a sheath composed of PVC (polyvinyl chloride) having a thickness of 0.4 mm. Thus, a non-foamed and non-crosslinked coaxial cable having impedance of 50Ω was fabricated.
Coaxial cables were fabricated in the same manner as Example 38 with the exception of using the base resins shown in Table 6.
Molten mixtures were obtained by loading the base resins, antioxidant and metal deactivator shown in Table 6 into an extruder (product name: LABOPLASTOMILL 4C150, twin-screw segmented extruder 2D30W2, screw diameter (D): 25 mm, effective screw length (L): 750 mm, manufactured by Toyo Seiki Seisaku-Sho, Ltd.) in the incorporated amounts shown in Table 6 (units: parts by mass) followed by melting and kneading. At this time, the melting and kneading temperature was 200° C.
The above-mentioned molten mixtures were further melted and kneaded with an extruder (screw diameter (D): 25 mm, effective screw length (L): 800 mm, manufactured by Hijiri Manufacturing Ltd.) set to a temperature of 200° C. and extruded into the shape of a tube. Tin-plated copper wires having a diameter of 0.172 mm were then covered with these tubular extrudates. Thus, insulated wires were fabricated that were composed of a conductor and an insulating layer covering the conductor. At this time, the extrudates were extruded so that the outer diameter of the insulating layer was 0.6 mm and the thickness was 0.215 mm.
Coaxial cables were then fabricated in the same manner as Example 38 using the insulated wires obtained in this manner.
Furthermore, the products indicated below were specifically used for the base resins, antioxidant and metal deactivator shown in Table 6.
(1) Base Resins
(1-1) WFX4 (WINTEC, Manufactured by Japan Polypropylene Corporation)
(1-2) WFW4 (WINTEC, Manufactured by Japan Polypropylene Corporation)
(1-3) WMG03 (WINTEC, Manufactured by Japan Polypropylene Corporation)
(1-4) WFX6 (WINTEC, Manufactured by Japan Polypropylene Corporation)
(1-5) FX4G (NOVATEC-PP, Manufactured by Japan Polypropylene Corporation)
(1-6) FW4B (NOVATEC-PP, manufactured by Japan Polypropylene Corporation)
(2) Antioxidant
(2-1) ADK STAB AO-80, Manufactured by ADEKA CORPORATION
(3) Metal Deactivator
(3-1) CDA-1 (ADK STAB CDA-1, Manufactured by ADEKA CORPORATION)
[Characteristics Evaluation]
The following characteristics were evaluated for the coaxial cables obtained in Examples 38 to 46 and Comparative Examples 14 to 17.
(1) Crystallization Peak Temperature, Melting Heat Peak Temperature (Melting Point) and Degree of Crystallization.
Crystallization peak temperature and melting heat peak temperature were calculated in the same manner as Example 1. The results are shown in Table 6. In addition, degree of crystallization was also calculated in the same manner as Example 1. The results are shown in Table 6.
(2) Dielectric Characteristics (tan δ)
Dielectric characteristics were investigated by measuring dielectric tangent (tan δ). Dielectric tangent (tan δ) was respectively measured at measuring frequencies of 3.0 GHz, 6.9 GHz, 10.7 GHz and 14.6 GHz in the same manner as Example 1. The results are shown, in Table 7. Acceptance criteria for tan δ at each frequency were the same as the criteria applied in Examples 1 to 27 and Comparative Examples 1 to 9.
(3) Attenuation
Attenuation was measured in the same manner as Example 1 for the coaxial cables obtained in Examples 38 to 46 and Comparative Examples 14 to 17. The results are shown in Table 7.
(4) Heat Resistance
Crushing ratio was calculated in the same manner as Example 1 for the coaxial cables of Examples 38 to 46 and Comparative Examples 14 to 17, and the resulting crushing ratios were used, as an indicator of heat resistance. The results are shown in Table 7. Furthermore, a crushing ratio of less than 50% was judged to be acceptable in terms of having superior heat, resistance, while a crushing ratio of 50% or more was judged to be unacceptable in terms of having inferior heat resistance.
(5) Crush Resistance
Shore D hardness, which indicates surface hardness, was measured and this Shore D hardness was used as an indicator of crush resistance. The Shore D hardness of the insulated wires of Examples 38 to 46 and Comparative Examples 14 to 17 was measured in the same manner as Example 1. Results of measuring at a load holding time of 5 seconds are shown in Table 7. Crush resistance was judged to be acceptable in terms of superior crush resistance if the Shore D hardness was 63 or more, and judged to be unacceptable in terms of inferior crush resistance if the Shore D hardness was less than 63.
(6) Heat Aging Resistance Characteristics
Heat aging resistance characteristics were evaluated in the same manner as Example 1. Namely, tensile tests were carried out on the coaxial cables obtained in Examples 38 to 44 and Comparative Examples 14 to 17, and the number of days at which the measured, tensile strength reached 50% of the initial tensile strength or the number of days at which the measured elongation retention reached 50% of the initial elongation retention was calculated as a relative value in the case that the number of days for Example 1 in which antioxidant and metal deactivator were not used was set to a value of 100. The results are shown in Table 7.
(7) Bloom (Blooming)
Bloom was evaluated in the same manner as Example 1. The results are shown in Table 7. Furthermore, the criteria used to evaluate bloom were the same as the criteria applied in Examples 1 to 27 and Comparative Examples 1 to 9.
According to the results shown in Table 7, each of Examples 38 to 46 demonstrated low dielectric tangent, high Shore D hardness, and adequate heat resistance at the level of UL90° C., and satisfied acceptance criteria for all of dielectric characteristics, crush resistance and heat resistance. In contrast, Comparative Examples 14 to 17 did not satisfy acceptance criteria for at least one of dielectric characteristics, crush resistance and heat resistance.
Accordingly, according to the insulated wire corresponding to the third aspect, of the present invention, superior dielectric characteristics in the gigahertz band as well as superior crush resistance and heat resistance were confirmed to be able to be realized.
1 Internal conductor (conductor)
1
a Body portion
1
b Plating film
2 Insulating layer
5 Insulated wire
10,20 Cable
| Number | Date | Country | Kind |
|---|---|---|---|
| 2010-268854 | Dec 2010 | JP | national |
| 2010-268856 | Dec 2010 | JP | national |
| 2010-268857 | Dec 2010 | JP | national |
This application is a Continuation of National Stage of International Application No. PCT/JP2011/077672 filed Nov. 30, 2011, claiming priority based on Japanese Patent Applications No. 2010-268854 filed Dec. 1, 2010, No. 2010-268856 filed Dec. 1, 2010 and No. 2010-268857 filed Dec. 1, 2010, the contents of all of which are incorporated herein by reference in their entirety.
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/JP2011/077672 | Nov 2011 | US |
| Child | 13907155 | US |
