Electrical cable comprising a thermoplastic insulating layer based on a heterophasic propylene polymer

Abstract

The present invention relates to an electrical cable (1) comprising at least one electrically insulating layer (3) surrounding at least one elongated electrically conductive element (2), wherein said insulating layer (3) is obtained from a thermoplastic polymer composition comprising more than 10% by weight of a heterophasic propylene copolymer comprising a continuous thermoplastic phase based on at least one homo- or copolymer of propylene and an elastomeric phase dispersed in this continuous thermoplastic phase. Figure for the abstract: Fig. 1

Description

Title of the invention: Electrical cable comprising a thermoplastic insulating layer based on a heterophasic propylene polymer

[0001] The present invention relates to the field of electrical cables and more specifically to the field of electrically insulating polymer layers present in these cables. The invention more precisely relates to a polymer insulating layer obtained from a specific polymer composition, which provides the insulating layer with good electrical and mechanical performance, and in particular good flexibility.

[0002] The invention typically, but not exclusively, applies to electrical cables intended for the transport of energy, and in particular to low voltage power cables (namely carrying a direct or alternating current typically having a voltage less than or equal to 6 kV), and which can for example be used in the fields of aerial, submarine, terrestrial, or aeronautical electricity transport.

[0003] A low voltage power transmission cable preferably comprises: - an elongated electrically conductive element (for example a wire or a set of wires twisted together), in particular made of copper or aluminum; - an electrically insulating layer surrounding said elongated electrically conductive element; and - possibly an electrically insulating protective sheath surrounding said electrically insulating layer.

[0004] Historically, the insulating layers of such cables were polyethylene-based, particularly cross-linked polyethylene (XLPE), which has the disadvantage of not being recyclable. More recently, non-cross-linked thermoplastic insulating layers have been proposed, typically based on recyclable thermoplastic blends of polyethylene and polypropylene.

[0005] In this context, application WO2022 / 129814 described, in particular, non-crosslinked thermoplastic polymer compositions well suited for the formation of insulating layers for low-voltage cables, comprising (i) at least 50% by weight of a homophasic propylene polymer; (ii) at least one homophasic ethylene polymer present in a proportion lower than that of the homophasic propylene polymer and having an elastic modulus of more than 300 MPa; and (iii) optionally, up to a maximum of 10% by weight of a heterophasic propylene copolymer. WO2022 / 129814 indicates that, when it is Currently, the heterophasic propylene copolymer allows for better compatibility between the homophasic propylene polymer and the homophasic ethylene polymer.

[0006] Although they are very well suited for the constitution of insulating layers in low voltage cables that can operate at temperatures above 70°C and have very good thermomechanical and electrical performance, the compositions of WO2022 / 129814 nevertheless have lower performance in terms of flexibility.

[0007] An object of the present invention is to provide polymer compositions well suited for the constitution of insulating layers of low voltage cables, and having in particular adequate thermomechanical and electrical performance, and which also have better flexibility than the layers described in the aforementioned WO2022 / 129814 application.

[0008] To this end, the present invention proposes to use a polymer composition comprising a heterophasic propylene polymer of the type envisaged as a compatibilizing additive in application WO2022 / 129814, but using this copolymer not as a compatibilizing agent between two other incompatible polymers as is done in WO2022 / 129814, but using this copolymer as a constituent polymer of the composition, in particular with contents much higher than those envisaged in WO2022 / 129814.

[0009] More specifically, the present invention relates to an electrical cable comprising at least one electrically insulating layer surrounding at least one elongated electrically conductive element, wherein said insulating layer is obtained from a thermoplastic polymer composition comprising more than 10% by weight of a heterophasic propylene copolymer relative to the total weight of polymers in the thermoplastic polymer composition.

[0010] According to another aspect, the present invention relates to a method of applying a thermoplastic coating layer around at least one elongated electrically conductive element, said method comprising the application, in particular by extrusion, of a polymer composition comprising more than 10% by weight of a heterophasic propylene copolymer relative to the total weight of polymers in the thermoplastic polymer composition.

[0011] According to a particular aspect, the insulating layer is obtained from a thermoplastic polymer composition comprising at least 90% by weight, for example at least 95% by weight, of heterophasic propylene copolymer relative to the total weight of polymers in the heterophasic polymer composition.

[0012] According to a first interesting embodiment, the insulating layer of the cable according to the invention is obtained from a thermoplastic polymer composition comprising heterophasic propylene copolymer as the sole polymer (or substantially as the sole polymer). According to this embodiment, the composition typically comprises heterophasic propylene copolymer at least 90% by weight, preferably at least 95%, or even at least 98% by weight and more preferably at least 99% by weight relative to the total weight of polymers in the polymer composition (the composition may optionally contain a very small proportion of one or more other polymers, for example as additives or impurities). According to a particular variant, the polymer composition comprises heterophasic propylene copolymer as the sole polymer (at a content of 100% by weight relative to the total weight of polymers in the polymer composition), to the exclusion of any other polymer in the composition.

[0013] According to a second possible embodiment, the insulating layer is obtained from a thermoplastic polymer composition obtained by mixing heterophasic propylene copolymer with a homophasic propylene polymer. According to this embodiment, the heterophasic propylene copolymer is preferably present at a content much greater than 10% by weight relative to the total weight of the polymers in the mixture, and the homophasic polypropylene is at a content much less than 90%. Typically, the polymer composition according to this second embodiment is obtained from a mixture comprising the heterophasic propylene copolymer at a content of 15% to 90% by weight (for example, between 20% and 80% by weight or between 25% and 70% by weight), this content being, for example, at least 30% by weight, in particular at least 40% by weight, or even at least 50% by weight relative to the total mass of the polymers in the composition.According to this second embodiment, the composition generally comprises homophasic polypropylene at a content of 10 to 85% or less by weight (for example, between 20 and 80% by weight or between 20 and 75% by weight), this content being, for example, less than or equal to 70% by weight, in particular less than or equal to 60% by weight, in particular less than or equal to 50% by weight relative to the total mass of the polymers in the composition. The composition according to this second embodiment may optionally comprise polymers other than the heterophasic propylene copolymer and homophasic polypropylene. These other polymers are preferably thermoplastic polymers, generally present at a level of less than 20% by weight, more preferably less than 15% by weight relative to the total weight of the polymers in the composition.According to one possible variant, the polymer composition may, for example, include a small proportion of a homophasic ethylene polymer, typically less than 20% by weight, for example between 0.1 and 10%, by weight relative to the total weight of the polymers in the composition. According to another variant, the polymer composition... is substantially free from homophasic ethylene polymer (or even totally free from homophasic ethylene polymer) with a homophasic ethylene polymer content of less than 0.5% by weight relative to the total weight of the polymers in the composition, this content preferably being less than 0.1%, or even zero)

[0014] The work carried out by the inventors in the context of the present invention has now made it possible to demonstrate that an insulating layer based on a heterophasic propylene copolymer as used in the conditions of the invention (in particular according to the first and second embodiments mentioned above) proves to be suitable in a low voltage cable, including for operation at temperatures exceeding 70°C, and that the insulating layer has interesting electrical and thermomechanical properties, with in addition good performance in terms of flexibility.

[0015] Various features of the invention and various possible variants are described in more detail below.

[0016] Heterophase propylene polymer

[0017] The polymer composition from which the insulating layer of the cable of the invention is formed specifically comprises a heterophasic propylene copolymer. This propylene copolymer, referred to as "heterophasic" (or also "heterophasic"), comprises two distinct phases, typically: - a continuous thermoplastic phase based on polypropylene (this is a thermoplastic matrix based on at least one homo- or co-polymer of propylene); and - an elastomeric phase (generally both elastomeric and thermoplastic) dispersed in this continuous thermoplastic phase (matrix).

[0018] This heterophasic mixture can be introduced into the composition in the form of a preformed heterophasic mixture (typically in the form of a commercial biphasic mixture, generally referred to as a "heterophasic copolymer" - in this case, the mixture can for example be introduced into an extruder in the form of granules each consisting of this heterophasic mixture).Alternatively, the two phases of the heterophasic mixture can be formed in situ following the mixing of their constituent polymers in proportions leading to the dispersion of the elastomer phase in the continuous thermoplastic polypropylene-based phase (for example by introducing into an extruder (i) granules comprising the first homophasic polymer (or a homophasic mixture of polymers) constituting the continuous thermoplastic phase, and (ii) other granules not comprising the first polymer and comprising a second homophasic polymer (or a second homophasic mixture of polymers) constituting the continuous phase).

[0019] The heterophasic copolymer used according to the invention comprises at least two distinct phases: one comprising a polymer matrix, and the other typically comprising particles or nodules dispersed within this polymer matrix. This type of polymer can be easily identified by techniques well known to those skilled in the art, such as scanning electron microscopy (SEM). More particularly, at a magnification of x 10,000, it is common to observe said particles or nodules dispersed within said polymer matrix, said particles having an average size ranging from 200 nm to 10 pm, for example, between 500 nm and 2 pm.

[0020] The thermoplastic phase constituting the matrix of the heterophasic propylene copolymer generally represents between 50 and 85% by weight, advantageously between 55 and 80% by weight and for example between 55 and 75% by weight relative to the total weight of the heterophasic propylene copolymer.

[0021] The thermoplastic elastomer phase of the heterophasic propylene copolymer advantageously represents at least 15% by weight, preferably at least 20% and for example at least 30% and generally less than 50% by weight, for example less than 45% by weight relative to the total weight of the heterophasic propylene copolymer.

[0022] According to a first possible embodiment, the elastomer phase which is dispersed in a continuous thermoplastic phase based on polypropylene comprises an elastomer copolymer of ethylene and an olefin other than ethylene, in particular an elastomer copolymer of ethylene and propylene.

[0023] The heterophasic propylene copolymer used according to this first embodiment preferably has an elastic modulus ranging from approximately 50 to 1200 MPa, and particularly preferably: either an elastic modulus ranging from approximately 50 to 550 MPa, and more particularly preferably ranging from approximately 50 to 300 MPa.

[0024] The heterophasic propylene copolymer used according to this first embodiment is generally introduced into the polymer composition as a preformed heterophasic mixture. As an example of a preformed heterophasic propylene copolymer useful according to this first embodiment, one can mention the heterophasic propylene copolymers marketed by LyondellBasell under the references Adflex® Q 200 F, Hifax CA 10A, or Hifax CA 12A.

[0025] The heterophasic propylene polymer according to the first mode described above preferably has a melting temperature above about 140°C, particularly preferably above about 145°C, and more particularly preferably from about 150 to 175°C.

[0026] The heterophasic propylene polymer according to the first mode described above can have an enthalpy of fusion ranging from approximately 20 to 100 J / g, and preferably from approximately 20 to 50 J / g.

[0027] The heterophasic propylene polymer according to the first mode described above can have a melt flow index ranging from 0.5 to 5 g / 10 min, and preferably from approximately 0.6 to 2 g / 10 min; in particular determined at approximately 230°C with a charge of approximately 2.16 kg according to ASTM D1238-00, or ISO 1133.

[0028] The heterophasic propylene polymer according to the first mode described above can have a density of approximately 0.81 to 0.92 g / cm3, preferably of 0.85 to 0.91 g / cm3, and particularly preferably of 0.87 to 0.91 g / cm3; in particular determined according to ISO 1183A (at a temperature of 23°C).

[0029] According to a second possible embodiment, the elastomeric phase dispersed in a continuous thermoplastic polypropylene-based phase comprises an ethylene elastomeric copolymer and at least one co-monomer bearing a polar group. In this embodiment, the elastomeric phase preferably represents at most 45% by weight (typically between 25 and 45%) relative to the total weight of the heterophasic propylene copolymer, the matrix representing at least 55% by weight (typically between 55 and 75%).

[0030] The heterophasic propylene copolymer used according to this first embodiment can optionally be introduced into the polymer composition in the form of a preformed heterophasic mixture. Alternatively, according to this second embodiment, the polymer composition can be obtained by a mixture of (i) the homo- or copolymer of propylene constituting the continuous phase based on polypropylene (typically introduced into an extruder in the form of first granules) and (ii) the ethylene elastomeric polymer and at least one co-monomer bearing a polar group (typically introduced into an extruder in the form of second granules distinct from the first), in which case the heterophasic mixture is formed in situ in the composition (typically by melting and mixing the granules in the extruder).

[0031] The elastomeric copolymer of ethylene and at least one monomer bearing polar groups used in the second mode described above may in particular have a melting temperature below 110°C, for example less than or equal to 100°C.

[0032] The elastomeric copolymer of ethylene and at least one monomer bearing polar groups used in the second mode may, in particular, be a polymer bearing one or more polar functions selected from among the acetate, acrylate, hydroxyl, nitrile, carboxyl, carbonyl, ether, ester, silane groups and their mixtures. A useful homophasic ethylene polymer with polar characteristics according to the invention may, in particular, be: - a copolymer of ethylene and vinyl acetate (EVA); - an ethylene butyl acrylate (EBA) copolymer; - a copolymer of ethylene and ethyl acrylate (EEA); - a copolymer of ethylene and methyl acrylate (EMA); - a copolymer of ethylene and acrylic acid (EAA); or a mixture of these compounds.

[0033] The additional homophasic propylene polymer (optional)

[0034] For the purposes of this description, "homophasic polymer" means a polymer in the form of a single phase, generally a substantially homogeneous phase. Such a homophasic polymer within the meaning of this description is not a heterophasic polymer, which excludes, for example, heterophasic propylene copolymers of the type described in document WO2011 / 092533, namely the Adflex Q200F or Hifax CA 7441A (LyondellBasell) copolymers.

[0035] Such a homophasic propylene polymer may optionally be added to the polymer composition when the latter already includes a preformed heterophasic copolymer. In other words, according to this embodiment, the polymer composition is formed by a mixture of (i) a preformed heterophasic propylene copolymer and (ii) an additional homophasic propylene copolymer. The mixing of the initially separate polymers (i) and (ii) is typically carried out by mixing initial granules comprising the heterophasic mixture (i) with other granules comprising the additional homophasic propylene copolymer.

[0036] According to one possible embodiment, the additional homophasic propylene polymer is a polypropylene homopolymer.

[0037] Alternatively, according to another conceivable mode, the homophasic propylene polymer is a propylene copolymer.

[0038] Examples of homophasic propylene copolymers usable according to the invention include copolymers of propylene and an olefin other than propylene, this olefin being able in particular to be chosen from ethylene or an olefin different from propylene.

[0039] The olefin other than propylene present in a useful homophasic propylene copolymer according to the invention represents preferably at most 45% by mole, particularly preferably at most 35% by mole, more particularly preferably at most 20% by mole, and more particularly preferably at most 10% by mole, relative to the total amount of monomers in the copolymer of homophasic propylene. This is particularly the case when the olefin other than propylene is ethylene or an olefin different from propylene.

[0040] According to an advantageous embodiment, the olefin other than propylene present in a useful homophasic propylene copolymer according to the invention represents at least approximately 1 mole percent relative to the total number of moles of monomers in the homophasic propylene copolymer. This is particularly the case when the olefin other than propylene is ethylene or an olefin other than propylene.

[0041] The molar content (percentage in moles) of the olefin other than propylene present in a useful homophasic propylene copolymer according to the invention can in particular be determined by nuclear magnetic resonance (NMR), for example according to the method described in Masson et al., Int. J. Polymer Analysis & Characterization, 1996, Vol.2, 379-393.

[0042] The olefin different from propylene present in a useful homophasic propylene copolymer according to the invention may in particular correspond to the formula CH2=CH-R1, in which R1 is a linear or branched alkyl group having from 2 to 12 carbon atoms, in particular selected from the following olefins: 1-butene, 1-pentene, 4-methyl-1-pentene, 1-hexene, 1-octene, 1-decene, 1-dodecene, and a mixture thereof.

[0043] Propylene and ethylene copolymers are preferred as homophasic propylene copolymers.

[0044] The homophasic propylene copolymer is advantageously a statistical copolymer.

[0045] As an example of a useful homophasic statistical copolymer of propylene according to the invention, we can cite that marketed by the company Borealis under the reference Bormed® RB 845 MO, that marketed by the company Total Petrochemicals under the reference PPR 3221, that marketed by the company Sabic under the reference PP 620P, or that marketed by the company Repsol Isplen under the reference RC530S2E.

[0046] The useful homophasic propylene polymer can be characterized by its elastic modulus. This elastic modulus (or Young's modulus, also known by the English term "Tensile Modulus") is well known to those skilled in the art and can be easily determined according to ISO 527-1, -2 (2012). ISO 527 has a first part, designated "ISO 527-1", and a second part, designated "ISO 527-2", specifying the test conditions relating to the general principles of the first part of ISO 527.

[0047] A useful homophasic propylene homopolymer according to the invention preferably has an elastic modulus ranging from 1250 to 1600 MPa.

[0048] A useful homophasic propylene copolymer according to the invention preferably has an elastic modulus ranging from 600 to 1200 MPa, and particularly preferably ranging from 800 to 1100 MPa.

[0049] Furthermore, a useful homophasic propylene polymer according to the invention advantageously has a melting temperature above 130°C, particularly preferably above 135°C, and more particularly preferably ranging from approximately 140 to 175°C.

[0050] A useful homophasic propylene polymer according to the invention may also have an enthalpy of fusion ranging from approximately 20 to 100 J / g. When it is a homophasic propylene homopolymer, its enthalpy of fusion is preferably from 80 to 90 J / g. When it is a homophasic propylene copolymer, it preferably has an enthalpy of fusion ranging from 40 to 90 J / g and, particularly preferably, from 50 to 85 J / g.

[0051] A useful homophasic propylene polymer according to the invention may also have a melt flow index ranging from 0.5 to 3.5 g / 10 min, preferably ranging from 1.0 to 2.8 g / 10 min, and particularly preferably ranging from 1.2 to 2.5 g / 10 min; in particular determined at approximately 230°C with a charge of approximately 2.16 kg according to ASTM D1238-00, or ISO 1133.

[0052] A useful homophasic propylene polymer according to the invention may also have a density ranging from approximately 0.81 to 0.92 g / cm3, preferably ranging from 0.85 to 0.91 g / cm3, and particularly preferably ranging from 0.87 to 0.91 g / cm3; in particular determined according to ISO 1183A (at a temperature of 23°C).

[0053] The homophasic propylene polymer can represent from 55 to 90% by weight approximately, and particularly preferably from 60 to 80% by weight approximately, relative to the total weight of polymers in the polymer composition.

[0054] The additional homophasic ethylene polymer (optional)

[0055] The polymer composition may optionally result from a mixture of the polymers previously described (heterophasic propylene copolymer, plus optionally an additional homophasic polymer) with an additional homophasic ethylene polymer present in a small proportion, typically less than 20% by weight relative to the total weight of the polymers in the composition.

[0056] This additional homophasic ethylene polymer, when present in the composition, is typically a homopolymer or a copolymer of ethylene. It preferably comprises at least approximately 80 mole percent of ethylene, particularly preferably at least approximately 90 mole percent of ethylene, and even more preferably at least approximately 95 mole percent of ethylene, relative to the total number of moles of monomers in the ethylene polymer.

[0057] When such an additional homophasic ethylene polymer is present, it typically has an elastic modulus of at least 300 MPa, preferably an elastic modulus of at least 325 MPa, and particularly preferably of at least 350 MPa. This elastic modulus generally remains less than or equal to 600 MPa, for example less than or equal to 500 MPa.

[0058] When a homophasic ethylene polymer is present in the composition, its melt flow index advantageously ranges from 0.5 to 5 g / 10 min, and preferably from 1 to 3 g / 10 min (the melt flow index referred to here is that determined at approximately 230°C with a charge of 2.16 kg according to ASTM D1238-00, or ISO 1133).

[0059] When a homophasic ethylene polymer is present in the composition, it may, for example, be a low-density polyethylene, a linear low-density polyethylene, a medium-density polyethylene, or a high-density polyethylene; in particular according to ISO 1183A (at a temperature of 23°C).

[0060] In this description, the expression "low density polyethylene" refers to a homophasic ethylene polymer having a density ranging from approximately 0.91 to 0.925 g / cm3, said density being measured according to ISO 1183A (at a temperature of 23°C).

[0061] In this description, the expression "medium density polyethylene" refers to a homophasic ethylene polymer having a density ranging from approximately 0.926 to 0.940 g / cm3, said density being measured according to ISO 1183A (at a temperature of 23°C).

[0062] In this description, the expression "high-density polyethylene" refers to a homophasic ethylene polymer having a density ranging from 0.941 to 0.965 g / cm3, said density being measured according to ISO 1183A (at a temperature of 23°C).

[0063] When a homophasic ethylene polymer is present in the composition, it may advantageously be a polyethylene having a density of at most 0.936 g / cm3, particularly preferably of at most 0.930 g / cm3, and more particularly preferably of at most 0.925 g / cm3; said density being measured in particular according to ISO 1183A (at a temperature of 23°C), and the homophasic ethylene polymer is then advantageously a low-density polyethylene, a linear low-density polyethylene, or a medium-density polyethylene, and particularly preferably a linear low-density polyethylene.

[0064] As an example of linear low-density polyethylene, we can cite that marketed by Exxon under the reference LL 1004YB, that marketed by Sabic under the reference 318B, or that marketed by Versalis under the reference Flexirene CL 10.

[0065] The homophasic ethylene polymer, when present, is typically present at a content between 0.1 and 20%, for example between 0.5 and 10% by weight relative to the total weight of the polymers in the composition.

[0066] When the composition includes a homophasic ethylene polymer, it generally also systematically includes a homophasic propylene polymer, with a mass proportion (i.e., a quantity by weight) of the homophasic propylene polymer that preferably remains strictly greater than the mass proportion (i.e., the quantity by weight) of the homophasic ethylene polymer, relative to the total weight of polymers in the polymer composition.

[0067] Possible other polymers

[0068] The polymer composition from which the insulating layer of the cable of the invention is formed may optionally include other polymers in addition to the aforementioned polymers.

[0069] However, according to a preferred embodiment of the invention, the polymer composition comprises less than 20% (for example, less than 15%, or even less than 10%) by weight of polymer other than a heterophasic propylene copolymer, a homophasic propylene polymer, or a homophasic ethylene polymer relative to the total weight of polymers in the composition.

[0070] Furthermore, the polymer composition from which the insulating layer of the cable of the invention is formed is a thermoplastic polymer composition. It is therefore not cross-linkable. The insulating layer of the cable of the invention is also a thermoplastic polymer layer, which is therefore not cross-linked.

[0071] In particular, the polymer composition from which the insulating layer of the cable of the invention is formed does not include crosslinking agents, silane-type coupling agents, peroxides and / or additives that allow crosslinking.

[0072] Furthermore, it is preferable that the polymer composition from which the insulating layer of the cable of the invention is formed does not include olefin polymers grafted with crosslinkable functions, such as, for example, vinyl silane olefin polymers.

[0073] Given its thermoplastic nature, the insulating layer of the cable of the invention generally has the advantage of being recyclable.

[0074] Optional additives

[0075] The polymer composition from which the insulating layer of the cable of the invention is formed may optionally include one or more additives in addition to the aforementioned polymers.

[0076] These additives may in particular be chosen from among processing aids such as lubricants, compatibilizing agents, coupling agents, antioxidants, anti-UV agents, antioxidants, anti-copper agents, anti-water treeing agents, pigments, and mixtures thereof.

[0077] The polymer composition preferably comprises at least one antioxidant and / or at least one anti-copper agent (also called a metal deactivator).

[0078] The polymer composition can typically comprise from 0.01 to 5% by weight about, and preferably from 0.1 to 2% by weight about, of additives, relative to the total weight of the polymer composition.

[0079] Antioxidants help to protect the polymer composition from thermal stresses generated during the cable manufacturing or cable operation stages.

[0080] The antioxidants are preferably chosen from among hindered phenols, thioesters, sulfur-based antioxidants, phosphorus-based antioxidants, amine-type antioxidants, and a mixture thereof.

[0081] Examples of hindered phenols include 1,2-bis(3,5-di-tert-butyl-4-hydroxyhydrocinnamoyl)hydrazine (Irganox® MD 1024), pentaerythritol tetrakis(3-(3,5-di-terLbutyl-4-hydroxyphenyl)propionate) (Irganox® 1010), octadecyl 3-(3,5-di-terLbutyl-4-hydroxyphenyl)propionate (Irganox® 1076), 1,3,5-trimethyl-2,4,6-tris(3,5-di-terLbutyl-4-hydroxybenzyl)benzene (Irganox® 1330), 4,6-bis(octylthiomethyl)-o-cresol (Irgastab® KV10 or Irganox® 1520), 2,2'-thiobis(6-tert-butyl-4-methylphenol) (Irganox® 1081), 2,2'-thiodiethylene bis[3-(3,5-di-tert-butyl-4-hydroxyphenyl) propionate] (Irganox® 1035), tris (3,5-di-tert-butyl-4-hydroxybenzyl) isocyanurate (Irganox® 3114), 2,2'-oxamido-bis(ethyl-3(3,5-di-terL butyl-4-hydroxyphenyl)propionate) (Naugard XL-1), or 2,2'-methylenebis(6-tert-butyl-4-methylphenol).

[0082] Examples of sulfur-based antioxidants include thioethers such as didodecyl-3,3'-thiodipropionate (Irganox® PS800), distearyl thiodipropionate or dioctadecyl-3,3'-thiodipropionate (Irganox® PS802), bis[2-methyl-4-{3-n-alkyl (Ci2 or CM) thiopropionyloxy}-5-tert-butylphenyl]sulfide, thiobis-[2-tert-butyl-5-methyl-4,l-phenylene]bis[3-(dodecylthio)propionate], or 4,6-bis(octylthiomethyl)-o-cresol (Irganox® 1520 or Irgastab® KV10).

[0083] Examples of phosphorus-based antioxidants include tris(2,4-di-tert-butyl-phenyl) phosphite (Irgafos® 168) or bis(2,4-di-tert-butylphenyl)penta erythritol diphosphite (Ultranox® 626).

[0084] Examples of amine-type antioxidants include phenylenediamines (e.g., paraphenylenediamines such as 1PPD or 6PPD), styrene diphenylamines, diphenylamines, and 4-(l-methyl-l-phenylethyl)-N-[4-(l-methyl-l- phenylethyl)phenyl]aniline (Naugard 445), mercaptobenzimidazoles, or polymerized 2,2,4-trimethyl-1,2 dihydroquinoline (TMQ).

[0085] As examples of usable antioxidant mixtures according to the invention, Irganox B 225, which comprises an equimolar mixture of Irgafos 168 and Irganox 1010 as described above, can be cited.

[0086] The metal deactivator can be chosen from nitrogen-containing aromatic heterocycles and aromatic compounds comprising at least one -NH-C(=O)- functional group, and preferably from aromatic compounds comprising at least one -NH-C(=O)- functional group. The presence of oxygen in the metal deactivator is important for the long-term immobilization of metal ions.

[0087] The metal deactivator is preferably different from a hindered amine. In other words, the metal deactivator preferably does not comprise one or more tetramethylpiperidine groups.

[0088] Examples of nitrogen-containing aromatic heterocyclics include quinoline derivatives such as polymerized 2,2,4-trimethyl-1,2-dihydroquinolines (TMQ).

[0089] Examples of aromatic compounds comprising at least one -NH-C(=O)- function include those comprising two -NH-C(=O)- functions, preferably comprising two covalently linked -NH-C(=O)- functions, and more particularly preferably comprising a divalent group -NH-C(=O)-C(=O)-NH- or -C(=O)-NH-NH-C(=O)-, such as 2,2'-oxamidobis-[ethyl-3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate] (Naugard XL-1), 2'-,3-bis[[3-[3,5-di-tert-butyl-4-hydroxyphenyl]propionyl]]propionohydrazide or 1,2-bis(3,5-di-tert-butyl-4-hydroxyhydrocinnamoyl)hydrazine (Irganox®) 1024 or Irganox® MD 1024), or oxalyl bis(benzylidenehydrazide) (OABH).

[0090] Some metal deactivators are also antioxidants.

[0091] In particular, when the insulating layer of the cable of the invention is intended for a low voltage application, it is preferable that the polymer composition from which the insulating layer is formed be free of dielectric liquid, in particular liquids selected from a mineral oil (e.g. naphthenic oil, paraffinic oil or aromatic oil), a vegetable oil (e.g. soybean oil, linseed oil, rapeseed oil, corn oil or castor oil), a synthetic oil such as an aromatic hydrocarbon (alkylbenzene, alkylnaphthalene, alkylbiphenyl, alkyldiarylethylene, for example), a silicone oil, an ether, an organic ester, and an aliphatic hydrocarbon.

[0092] The electrically insulating layer

[0093] The electrically insulating layer of the cable of the invention, obtained from the polymer composition defined in the preceding paragraphs, is a thermoplastic layer, preferably non-crosslinked.

[0094] For the purposes of this description, the term "non-crosslinked layer" means a layer whose gel content according to ASTM D2765-01 (xylene extraction) is preferably not more than about 30%, preferably not more than about 20%, particularly preferably not more than about 10%, more particularly preferably not more than 5%, and even more particularly preferably 0%.

[0095] The electrically insulating layer of the cable of the invention, preferably non-crosslinked, has a tensile strength (RT) of at least 8.5 MPa, preferably of at least 10 MPa approximately, and particularly preferably of at least 15 MPa approximately, before aging (according to IEC 20-86).

[0096] According to a particular embodiment, the electrically insulating layer, preferably non-crosslinked, has an elongation at break (ER) of at least about 250%, preferably about at least about 300%, and particularly preferably about at least about 350%, before aging (according to IEC 20-86).

[0097] In a particular embodiment, the electrically insulating layer, preferably non-crosslinked, has a tensile strength (RT) of at least 8.5 MPa, preferably of at least about 10 MPa, and particularly preferably of at least about 15 MPa, after aging (according to IEC 20-86 standard).

[0098] In a particular embodiment, the electrically insulating layer, preferably non-crosslinked, has an elongation at break (ER) of at least about 250%, preferably about at least about 300%, and particularly preferably about at least about 350%, after aging (according to IEC 20-86).

[0099] Tensile strength (RT) and elongation at break (ER) (before or after aging) can be carried out according to Standard NF EN 60811-1-1, in particular using a device marketed under reference 3345 by the company Instron.

[0100] Aging is generally carried out at 135°C for 240 hours (or 10 days).

[0101] The electrically insulating layer of the cable of the invention is preferably a recyclable layer.

[0102] The electrically insulating layer of the invention can be an extruded layer, in particular by processes well known to those skilled in the art.

[0103] The electrically insulating layer has a variable thickness depending on the type of cable considered. In particular, when the cable according to the invention is a low-voltage cable, the thickness of the electrically insulating layer is generally about 1 to 2 mm. The aforementioned thicknesses depend on the size of the elongated electrically conductive element.

[0104] In the present invention, the term "electrically insulating layer" means a layer whose electrical conductivity can be at most 1 x 10⁸ S / m (siemens per meter), preferably of at most 1.10 9 S / m, and particularly preferably of at most 1.10 10 S / m, measured at approximately 25°C in direct current.

[0105] The electrically insulating layer of the invention may comprise at least the homophasic propylene polymer, at least the homophasic ethylene polymer, optionally the heterophasic propylene polymer, and optionally the dielectric liquid, the aforementioned ingredients being as defined in the invention.

[0106] The proportions of the different ingredients in the electrically insulating layer can be identical to those described in the invention for these same ingredients in the polymer composition.

[0107] The cable of the invention relates more particularly to the field of electrical cables operating in direct current (DC) or alternating current (AC).

[0108] The cable employing the insulating layer of the invention

[0109] Preferably, the electrically insulating layer of the invention, obtained from the polymer composition defined in the preceding paragraphs, surrounds the elongated electrically conductive element.

[0110] The elongated electrically conductive element is typically positioned in the center of the cable.

[0111] The elongated electrically conductive element can be a single-core conductor such as, for example, a metal wire or a multi-core conductor such as a plurality of twisted (stranded together) or non-twisted metal wires.

[0112] The elongated electrically conductive element may in particular be made of aluminium, aluminium alloy, copper, copper alloy, or one of their combinations.

[0113] The cable may further comprise an outer protective sheath surrounding the electrically insulating layer.

[0114] The outer protective sheath can be in direct physical contact with the electrically insulating layer.

[0115] The outer protective sheath may be an electrically insulating sheath.

[0116] According to a particularly preferred embodiment of the invention, the electrically insulating layer is in direct physical contact with the elongated electrically conductive element.

[0117] Advantageously, the cable of the invention is a low-voltage cable. A cable according to the invention does not generally comprise a semiconductor layer. Brief description of the drawings

[0118] [Fig-1] The [Fig. 1] represents a cable according to the invention.

[0119] For reasons of clarity, only the essential elements for understanding the invention have been represented schematically, and this without regard to scale.

[0120] Figure 1 shows a low-voltage electrical cable 1 according to the invention, comprising a central elongated electrically conductive element 2, in particular made of copper or aluminum or one of their alloys. The electrical cable 1 further comprises an electrically insulating layer 3, and optionally an outer protective sheath 4.

[0121] The electrically insulating layer 3 is an extruded, non-crosslinked layer, obtained from a polymer composition according to the invention.

[0122] The presence of the outer protective sheath 4 is preferable, but not essential according to the invention.

Claims

Demands

1. Electric cable (1) comprising at least one electrically insulating layer (3) surrounding at least one elongated electrically conductive element (2), wherein said insulating layer (3) is obtained from a thermoplastic polymer composition comprising more than 10% by weight of a heterophasic propylene copolymer relative to the total weight of polymers in the thermoplastic polymer composition, said heterophasic propylene copolymer comprising: - a thermoplastic continuous phase based on at least one homo- or copolymer of propylene; and - an elastomeric phase dispersed in this thermoplastic continuous phase.

2. Electric cable according to claim 1, wherein the insulating layer (3) is obtained from a thermoplastic polymer composition comprising at least 90% by weight, for example at least 95% by weight, of heterophasic propylene copolymer relative to the total weight of polymers in the heterophasic polymer composition.

3. Electrical cable according to claim 2, wherein the insulating layer (3) is obtained from a thermoplastic polymer composition comprising heterophasic propylene copolymer as the sole polymer.

4. Electrical cable according to claim 1, wherein the insulating layer (3) is obtained from a thermoplastic polymer composition obtained by mixing heterophasic propylene copolymer with a homophasic propylene polymer.

5. Electrical cable according to claim 4, wherein the polymer composition comprises heterophasic propylene copolymer in a content of 15% to 90% by weight.

6. Electric cable (1) according to any one of claims 1 to 5 wherein the dispersed elastomeric phase comprises an ethylene elastomeric copolymer and an olefin other than ethylene, in particular an ethylene elastomeric copolymer and propylene.

7. Electric cable (1) according to any one of claims 1 to 5, wherein said dispersed elastomeric phase comprises an ethylene elastomeric copolymer and at least one polar group-bearing co-monomer.

8. Electrical cable according to any one of claims 1 to 7, wherein the dispersed thermoplastic elastomer phase represents from 15% to 50% by weight, for example from 15% to 45% by weight relative to the total weight of the heterophasic propylene copolymer.

9. Electrical cable according to any one of claims 1 to 8, wherein the thermoplastic phase of the heterophasic propylene copolymer represents between 50 and 85% by weight, for example between 55 and 75% relative to the total weight of the heterophasic propylene copolymer.

10. Electric cable according to any one of claims 1 to 9, wherein the electrically insulating layer is a non-crosslinked layer.

11. Electric cable according to any one of claims 1 to 10, wherein the electrically insulating layer is in direct physical contact with the elongated electrically conductive element.

12. Electric cable according to any one of claims 1 to 11, further comprising an outer protective sheath (4) surrounding the electrically insulating layer.

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