Keep up to date with our latest company news and relevant industry knowledge.
Time: 2025-03-14 16:24:55 Source: Henan Province Jianyun Cable Co., Ltd.
In the world of cable manufacturing, insulation materials play a critical role in ensuring safety, durability, and performance. A recent study published in Wire & Cable (December 2024) by researchers Deng Yiquan and Ke Kai explores an innovative approach to improving insulation compounds made from Chlorinated Polyethylene (CM) and Ethylene-Propylene-Diene Rubber (EPDM). The secret ingredient? Zinc Methacrylate (ZDMA), a compound that promises to enhance the properties of these rubber blends. This article summarizes the study’s findings, breaks them down into easy-to-understand insights, and offers an analysis of what this means for the cable industry—all while aiming to boost your understanding and our website’s ranking!
Before diving into the study, let’s get to know the key players:
The goal? Combine these materials to create a high-performance insulation compound for cables that’s tough, flexible, and easy to manufacture.
The researchers set out to see how ZDMA could improve CM/EPDM blends. They tested different ways of adding ZDMA—either mixing it in directly or creating it inside the rubber blend (called in-situ synthesis)—and varied its amount along with the peroxide (dicumyl peroxide, or DCP) used to cure the rubber. They looked at three main areas:
Here’s what they discovered, step by step.
Vulcanization is the process that turns soft rubber into a tough, usable material. The study found that ZDMA speeds up this process more effectively than typical crosslinking agents when used with DCP. As the amount of ZDMA increased, the rubber cured faster and formed a denser network of molecular bonds—think of it like tightening the weave of a fabric to make it stronger.
Adding ZDMA significantly boosted the rubber’s strength. The researchers tested tensile strength (how much force it takes to pull the rubber apart), elongation at break (how far it stretches before breaking), and tear strength (how well it resists ripping). The sweet spot? Using 4 parts per hundred rubber (phr) of ZDMA made in-situ, with a zinc oxide (ZnO) to methyl methacrylate (MMA) molar ratio of 0.8. At this level, the material was at its strongest and most flexible.
Here’s a look at the data:
Table 1: Mechanical Properties with In-Situ ZDMA (DCP = 3 phr)
| ZDMA (phr) | Tensile Strength (MPa) | Elongation at Break (%) | Tear Strength (kN/m) |
|---|---|---|---|
| 0 | 4.7 | 415 | 6.2 |
| 1 | 6.5 | 432 | 7.2 |
| 2 | 7.6 | 446 | 7.4 |
| 3 | 9.2 | 452 | 7.8 |
| 4 | 11.8 | 465 | 8.4 |
| 5 | 9.5 | 456 | 8.1 |
| 6 | 9.2 | 448 | 7.5 |
Note: Values are sourced from the study’s tables and represent in-situ synthesis results.
While ZDMA worked wonders up to a point, too much of it caused problems. When the dosage went above 5 phr, the rubber started sticking to the molds during processing—a manufacturer’s nightmare. This suggests there’s a balance to strike between boosting performance and keeping the production line running smoothly.
Cables often need to work in cold climates, so the study checked how ZDMA affects flexibility at low temperatures. Adding ZDMA improved the rubber’s ability to stay pliable in the cold, with in-situ synthesis outperforming direct addition. This is a big win for cables used in harsh winter conditions.
Table 2: Low-Temperature Brittleness (°C) with In-Situ ZDMA (DCP = 3 phr)
| ZDMA (phr) | -40°C | -30°C | -20°C | -10°C | 0°C |
|---|---|---|---|---|---|
| 0 | Fail | Fail | Fail | Pass | Pass |
| 1 | Fail | Pass | Pass | Pass | Pass |
| 2 | Pass | Pass | Pass | Pass | Pass |
| 3 | Pass | Pass | Pass | Pass | Pass |
| 4 | Pass | Pass | Pass | Pass | Pass |
| 5 | Pass | Pass | Pass | Pass | Pass |
| 6 | Pass | Pass | Pass | Pass | Pass |
Note: “Pass” means the material remained flexible without cracking.
After testing various combinations, the researchers came up with an optimized formula:
This mix delivered top-notch mechanical properties, good processing behavior, and reliable low-temperature performance—perfect for high-quality cable insulation.
So, why does ZDMA make such a difference? When mixed with DCP, ZDMA triggers a reaction that forms tiny polymer chains within the rubber. These chains graft onto the CM and EPDM molecules, creating a tighter, stronger network—like adding extra stitching to a quilt. The in-situ method, where ZDMA is made inside the rubber blend, ensures it spreads evenly, leading to better results than just tossing pre-made ZDMA into the mix.
The study also found that ZDMA forms nanoparticles within the rubber, acting like microscopic reinforcements. This boosts strength and flexibility, but only up to a point—too much ZDMA, and the rubber gets sticky and hard to handle.
This research is exciting because it introduces a new tool for making better rubber compounds. ZDMA outperforms traditional crosslinking agents, offering a way to create insulation that’s stronger, more flexible, and more resistant to cold—all critical for cables that need to last in tough conditions.
The in-situ synthesis method steals the show here. By forming ZDMA right inside the rubber, it integrates more seamlessly, leading to a more uniform and effective material. This could inspire manufacturers to rethink how they add reinforcements to rubber blends.
The study makes it clear that 4 phr of ZDMA is the magic number. Go higher, and you risk processing headaches like mold sticking. This balance is key—manufacturers need materials that perform well but don’t slow down production.
That mold-sticking issue at higher ZDMA levels is a red flag. It’s a reminder that lab success doesn’t always translate directly to the factory floor. Companies might need to tweak equipment or processes to handle ZDMA-enhanced blends effectively.
The improved low-temperature performance is a standout feature. For industries like construction, automotive, or energy, where cables face freezing temperatures, this could mean fewer failures and longer-lasting products.
The optimized formula isn’t just a lab experiment—it’s ready for action. Cable makers can use this as a blueprint to produce insulation that meets tough standards, potentially reducing costs and improving reliability.
If you’re in the cable industry or just curious about advanced materials, this study offers valuable insights. It shows how small changes—like adding ZDMA—can lead to big improvements in everyday products. For manufacturers, it’s a chance to upgrade their insulation game. For consumers, it could mean safer, more durable cables powering our homes and devices.
The application of Zinc Methacrylate in CM/EPDM blends is a breakthrough in rubber compounding. By fine-tuning the amount and method of adding ZDMA, researchers have unlocked a way to make cable insulation stronger, more flexible, and better suited to extreme conditions. While there are challenges to overcome, like managing processing issues, the potential benefits make this a development worth watching. Next time you plug in a device, you might just be relying on a cable boosted by ZDMA—proof that science is quietly revolutionizing the things we take for granted.
