Conductor jacket and its manufacturing process

Abstract

The present disclosure provides a process. In one embodiment, the process includes blending a broad molecular weight distribution (MWD) ethylene-based polymer having an I21 / I2 ratio of 55 to 85 with a narrow MWD ethylene-based polymer having an I21 / I2 ratio of 20 to 50. The process includes forming a blend component including 20 wt% to 45 wt% of the broad MWD ethylene-based polymer, 80 wt% to 55 wt% of the narrow MWD ethylene-based polymer, and optional carbon black. The blend component has a density of 0.925 g / cc to 0.955 g / cc and an I21 / I2 ratio of 30 to 55. The process includes extruding the blend component onto a conductor at a velocity greater than 1.02 m / sec and forming a conductor jacket having a surface smoothness of 30 μin to 80 μin.

Description

[Background technology]

[0001] A cable, such as a power cable or a communications cable, is a type of conductor that includes an inner conductive element, such as metal wire or glass fiber, and one or more outer layers for shielding and protection. The outermost layer of a cable is typically a protective layer called the outer sheath or jacket.

[0002] Ethylene-based polymers for cable jacketing are known. Ethylene-based polymers for use in cable jacketing must have good processability, such as good extrusion properties over a wide processing temperature range. Furthermore, such ethylene-based cable jacketing generally must have good mechanical properties. However, cable jacketing compounds made from ethylene-based solution resins (SR resins) do not process well in extrusion equipment, resulting in unacceptable surface smoothness at typical extrusion line speeds when compared to equivalent compounds based on broader molecular weight distribution (MWD) gas-phase polymerization resins (GP resins).

[0003] The art recognizes a need to diversify and expand the variety of polymer resins available for use in cable jacketing applications while maintaining adequate processability and suitable mechanical and performance properties. Summary of the Invention

[0004] This disclosure relates to a process for manufacturing conductor jackets, such as cable jackets, that improves the processability of SR resins by blending them with GP resins and subsequently extruding the blend to produce conductor jackets with acceptable surface smoothness and improved tensile properties.

[0005] The present disclosure provides a process. In one embodiment, the process includes blending a broad molecular weight distribution (MWD) ethylene-based polymer having an I21 / I2 ratio of 55 to 85 with a narrow MWD ethylene-based polymer having an I21 / I2 ratio of 20 to 50. The process includes forming a blend component including 20% ​​to 45% by weight of the broad MWD ethylene-based polymer, 80% to 55% by weight of the narrow MWD ethylene-based polymer, and optional carbon black. The blend component has a density of 0.925 g / cc to 0.955 g / cc and an I21 / I2 ratio of 30 to 55. The process includes extruding the blend component onto a conductor at a velocity greater than 1.02 m / sec and forming a conductor jacket having a surface smoothness of 30 μin to 80 μin.

[0006] The present disclosure provides another process. In one embodiment, the process includes blending a broad molecular weight distribution (MWD) ethylene-based polymer having an I21 / I2 ratio of 55 to 85 with a narrow MWD ethylene-based polymer having an I21 / I2 ratio of 20 to 50. The process includes forming a blend component including 20 wt% to 70 wt% of the broad MWD ethylene-based polymer, 80 wt% to 20 wt% of the narrow MWD ethylene-based polymer, and optional carbon black. The blend component has a density of 0.925 g / cc to 0.955 g / cc and an I21 / I2 ratio of 15 to 65. The process includes extruding the blend component onto a conductor at a velocity greater than 1.02 m / sec and forming a conductor jacket having a surface smoothness of 20 μin to 80 μin.

[0007] definition All references herein to the Periodic Table of the Elements shall refer to the Periodic Table of the Elements, published and copyrighted by CRC Press, Inc., 2003. Also, all references to Group(s) are to the Group(s) reflected in this Periodic Table of the Elements, using the IUPAC system for numbering the Groups. Unless stated or suggested by context or customary in the art to the contrary, all parts and percentages are by weight. For purposes of U.S. patent practice, the contents of any patents, patent applications, or publications referenced herein are hereby incorporated by reference in their entirety (or their equivalent U.S. versions are so incorporated by reference), particularly with respect to disclosures of synthetic techniques, definitions (to the extent not inconsistent with any definitions provided herein), and general knowledge in the art.

[0008] Numerical ranges disclosed herein include all values ​​from and including the lower and upper limit values. For ranges including explicit numerical values ​​(e.g., 1, or 2, or 3 to 5, or 6, or 7), any subrange between any two explicit numerical values ​​is also included (e.g., 1 to 2, 2 to 6, 5 to 7, 3 to 7, 5 to 6, etc.).

[0009] Unless otherwise stated, implicit from context, or customary in the art, all parts and percentages are by weight and all testing processes are current as of the filing date of this disclosure.

[0010] As used herein, the term "composition" refers to a mixture of materials that comprise the composition, as well as reaction products and decomposition products formed from the materials of the composition.

[0011] The terms "comprising," "including," "having," and their derivatives are not intended to exclude the presence of any additional component, step, or procedure, whether specifically disclosed or not. For the avoidance of doubt, all compositions claimed through the use of the term "comprising" may include any additional additives, adjuvants, or compounds, whether polymeric or otherwise, unless otherwise stated to the contrary. In contrast, the term "consisting essentially of" excludes from any subsequent recitation any other component, step, or procedure, except those that are not essential to operability. The term "consisting of" excludes any component, step, or procedure not specifically delineated or listed.

[0012] A "conductor" is one or more wires or one or more fibers for conducting heat, light, and / or electricity. Conductors may be single or multiple wires / fibers, or may be in stranded or tubular form. Non-limiting examples of suitable conductors include various metals, such as carbon, silver, gold, copper, and aluminum. Conductors may also be optical fibers made from either glass or plastic. Conductors may or may not be disposed within a protective sheath. A "cable" is a conductor in which two or more wires or two or more optical fibers are bundled together, optionally within a common insulating sheath. The individual wires or fibers within the sheath may be bare, covered, or insulated. Combination cables may contain both electrical wires and optical fibers. Cables may be designed for low, medium, and / or high voltage applications.

[0013] Density is measured in accordance with ASTM D 792 with values ​​reported in grams per cubic centimeter (g / cc or g / cm 3 ).

[0014] An "ethylene-based polymer" is a polymer containing greater than 50 weight percent polymerized ethylene monomer (based on the total weight of polymerizable monomers) and, optionally, may contain at least one comonomer. Ethylene-based polymers include ethylene homopolymers and ethylene copolymers (meaning units derived from ethylene and one or more comonomers). The terms "ethylene-based polymer" and "polyethylene" may be used interchangeably. Non-limiting examples of ethylene-based polymers (polyethylenes) include low-density polyethylene (LDPE) and linear polyethylene. Non-limiting examples of linear polyethylenes include linear low-density polyethylene (LLDPE), very low-density polyethylene (ULDPE), very low-density polyethylene (VLDPE), multicomponent ethylene-based copolymers (EPE), ethylene / α-olefin multiblock copolymers (also known as olefin block copolymers (OBC)), single-site catalyzed linear low-density polyethylene (m-LLDPE), substantially linear or linear plastomers / elastomers, medium-density polyethylene (MDPE), and high-density polyethylene (HDPE). Generally, polyethylene can be produced in gas-phase fluidized bed reactors, liquid-phase slurry process reactors, or liquid-phase solution process reactors using heterogeneous catalyst systems such as Ziegler-Natta catalysts, or homogeneous catalyst systems containing Group 4 transition metals and ligand structures such as metallocene, nonmetallocene metal centers, heteroaryl, heteroatom aryloxy ethers, and phosphinimine. Combinations of heterogeneous and / or homogeneous catalysts can also be used in either single-reactor or dual-reactor configurations.

[0015] "Ethylene plastomer / elastomer" refers to a polymer that contains ethylene-derived units and at least one C3-C 10The ethylene plastomer / elastomer is a substantially linear, or linear, ethylene / α-olefin copolymer containing a uniform short chain branching distribution comprising units derived from an α-olefin comonomer, or at least one C4-C8 α-olefin comonomer, or at least one C6-C8 α-olefin comonomer. The ethylene plastomer / elastomer has a density of 0.870 g / cc, or 0.880 g / cc, or 0.890 g / cc to 0.900 g / cc, or 0.902 g / cc, or 0.904 g / cc, or 0.909 g / cc, or 0.910 g / cc, or 0.917 g / cc. Non-limiting examples of ethylene plastomers / elastomers include AFFINITY™ plastomers and elastomers (available from The Dow Chemical Company), EXACT™ plastomers (available from ExxonMobil Chemical), Tafmer™ (available from Mitsui), Nexlene™ (available from SK Chemicals Co.), and Lucene™ (available from LG Chem Ltd.).

[0016] "High density polyethylene" (or "HDPE") is a polymer consisting of ethylene homopolymer, or at least one C4-C 10 An ethylene / α-olefin copolymer with an α-olefin comonomer or a C4 α-olefin comonomer and having a density greater than 0.94 g / cc, or 0.945 g / cc, or 0.95 g / cc, or 0.955 g / cc to 0.96 g / cc, or 0.97 g / cc, or 0.98 g / cc. HDPE can be a unimodal or multimodal copolymer. A "unimodal ethylene copolymer" is an ethylene / C4-C copolymer that has one distinct peak in gel permeation chromatography (GPC) to show the molecular weight distribution. 10 It is an alpha-olefin copolymer.

[0017] A "jacket" is a coating on a conductor.

[0018] "Linear low density polyethylene" (or "LLDPE") is a polyethylene containing units derived from ethylene and at least one C3-C 10 LLDPE is a linear ethylene / α-olefin copolymer containing a heterogeneous short-chain branching distribution, including units derived from an α-olefin comonomer, or at least one C4-C8 α-olefin comonomer, or at least one C6-C8 α-olefin comonomer. In contrast to conventional LDPE, LLDPE is characterized by little, if any, long-chain branching. LLDPE has a density of 0.916 g / cc to 0.925 g / cc. Non-limiting examples of LLDPE include TUFLIN™ linear low-density polyethylene resin (available from The Dow Chemical Company), DOWLEX™ polyethylene resin (available from Dow Chemical Company), and MARLEX™ polyethylene (available from Chevron Phillips).

[0019] "Low density polyethylene" (or "LDPE") is an ethylene homopolymer or at least one C3-C6 copolymer having a density between 0.915 g / cc and 0.925 g / cc and containing long chain branches with broad MWD. 10 LDPE is an ethylene / α-olefin copolymer containing an α-olefin or a C3-C4 α-olefin. LDPE is typically produced by high-pressure free-radical polymerization (tubular reactor or autoclave with a free-radical initiator). Non-limiting examples of LDPE include MarFlex™ (Chevron Phillips), LUPOLEN™ (LyondellBasell), and LDPE products from Borealis, Ineos, ExxonMobil, and others.

[0020] Medium density polyethylene (or "MDPE") is an ethylene homopolymer, or at least one C3-C6 copolymer, having a density between 0.926 g / cc and 0.940 g / cc. 10 It is an ethylene / α-olefin copolymer containing an α-olefin or a C3-C4 α-olefin.

[0021] The melt index (I2) is measured at 190°C under a load of 2.16 kg according to ASTM D1238.

[0022] The melt index (I0.5) is measured according to ASTM D 1238 at 190° C. under a load of 0.5 kg.

[0023] The melt index (I10) is measured at 190° C. under a load of 10.0 kg according to ASTM D-1238.

[0024] The melt index (I21) is measured according to ASTM D 1238 at 190°C under a load of 21.0 kg.

[0025] The index I21 / I2 or "I21 / I2 ratio." The I21 / I2 ratio is an indirect measure of the viscosity ratio at high and low shear rates, and indicates shear thinning behavior related to both molecular weight distribution (MWD) and the presence of long chain branching, each of which significantly affects processability. Generally, polyethylenes containing long chain branching have high melt strength and exhibit low viscosity under high shear rate conditions, allowing for higher processing speeds compared to polyethylenes with little or no long chain branching.

[0026] "Multicomponent ethylene-based copolymers" (or "EPEs") are copolymers containing units derived from ethylene and at least one C3-C6 copolymer, such as those described in patent documents USP 6,111,023, USP 5,677,383, and USP 6,984,695. 10The EPE resin contains units derived from an α-olefin comonomer, or at least one C4-C8 α-olefin comonomer, or at least one C6-C8 α-olefin comonomer. The EPE resin has a density of 0.905 g / cc, or 0.908 g / cc, or 0.912 g / cc, or 0.920 g / cc to 0.926 g / cc, or 0.929 g / cc, or 0.940 g / cc, or 0.962 g / cc. Non-limiting examples of EPE resins include ELITE™ reinforced polyethylene (available from The Dow Chemical Company), ELITE AT™ advanced technology resin (available from The Dow Chemical Company), SURPASS™ polyethylene (PE) resin (available from Nova Chemicals), and SMART™ (available from SK Chemicals Co.).

[0027] A "multimodal ethylene copolymer" is an ethylene / C4-C copolymer that has at least two distinct peaks in the GPC that indicate the molecular weight distribution. 10 It is an α-olefin copolymer. Multimodal includes copolymers with two peaks (bimodal) as well as copolymers with three or more peaks. Non-limiting examples of HDPE include DOW™ high density polyethylene (HDPE) resin (available from The Dow Chemical Company), ELITE™ reinforced polyethylene resin (available from The Dow Chemical Company), CONTINUUM™ bimodal polyethylene resin (available from The Dow Chemical Company), LUPOLEN™ (available from LyondellBasell), and HDPE products from Borealis, Ineos, and ExxonMobil.

[0028] As used herein, an "olefin-based polymer" is a polymer that contains greater than 50 mole percent polymerized olefin monomers (based on the total amount of polymerizable monomers) and may optionally contain at least one comonomer. Non-limiting examples of olefin-based polymers include ethylene-based polymers and propylene-based polymers.

[0029] A "polymer" is a compound prepared by polymerizing monomers, whether of the same or different types, resulting in polymerized form in multiple and / or repeating "units" or "mer units" that make up the polymer. Thus, the general term polymer, including the term homopolymer, is typically used to refer to a polymer prepared from only one type of monomer, while the term copolymer typically refers to a polymer prepared from at least two types of monomer. It also encompasses all forms of copolymers, such as random and block. The terms "ethylene / α-olefin polymer" and "propylene / α-olefin polymer" refer to the above-described copolymers prepared by polymerizing ethylene or propylene, respectively, and one or more additional polymerizable α-olefin monomers. While polymers are often referred to as "made from" one or more specified monomers, such as "based on" a particular monomer or type of monomer, or "comprising" a particular monomer content, it is understood that in this context, the term "monomer" refers to the polymerized residue of the specified monomer and not to the unpolymerized species. Generally, polymers herein are referred to in terms of "units" that are the polymerized form of the corresponding monomers.

[0030] A "propylene-based polymer" is a polymer that contains greater than 50 mole percent polymerized propylene monomer (based on the total amount of polymerizable monomers) and may optionally contain at least one comonomer.

[0031] "Single-site catalyzed linear low-density polyethylene" (or "m-LLDPE") is a polyethylene containing units derived from ethylene and at least one C3-C 10m-LLDPE is a linear ethylene / α-olefin copolymer containing a uniform short-chain branching distribution and containing units derived from an α-olefin comonomer, or at least one C4-C8 α-olefin comonomer, or at least one C6-C8 α-olefin comonomer. m-LLDPE has a density of 0.913 g / cc, or 0.918 g / cc, or 0.920 g / cc to 0.925 g / cc, or 0.940 g / cc. Non-limiting examples of m-LLDPE include EXCEED™ Metallocene PE (available from ExxonMobil Chemical), LUFLEXEN™ m-LLDPE (available from LyondellBasell), and ELTEX™ PF m-LLDPE (available from Ineos Olefins & Polymers).

[0032] Surface smoothness. Surface smoothness of the conductor sheath sex is measured in accordance with ANSI 1995 via a Surftest SV-400 Series 178 surface texture measuring instrument. The wire sample is placed in a V-block and the stylus (10 urn) is lowered to a specific starting position (applying approximately 1 gram of force to the wire). The measurement is taken by moving the stylus laterally at a fixed speed of 2 (millimeters per second). Four readings per wire sample and four samples are tested, which are then averaged with the value reported in μ-inches.

[0033] Tensile Properties. The present compositions can be characterized by their tensile strength at break (megapascals, MPa) and elongation at break (%) ("TE"). Tensile strength ("TS") and elongation at break are measured according to ASTM D638 test procedures on compression molded specimens prepared in accordance with ASTM D4703. Elongation at break, or elongation to break, is the strain of the specimen at break, expressed as a percentage.

[0034] As used herein, Tm or "melting point" (also referred to as melting peak in reference to the shape of the plotted DSC curve) is measured by DSC (differential scanning calorimetry) techniques for measuring the melting point or melting peak of polyolefins, as described in U.S. Pat. No. 5,783,638. It should be noted that many blends containing two or more polyolefins have more than one melting point or melting peak, and many individual polyolefins contain only one melting point or melting peak.

[0035] "Ultra low density polyethylene" (or "ULDPE") and "very low density polyethylene" (or "VLDPE") are polyethylenes containing units derived from ethylene and at least one C3-C 10 These are linear ethylene / α-olefin copolymers containing heterogeneous short-chain branching distributions containing units derived from an α-olefin comonomer, or at least one C4-C8 α-olefin comonomer, or at least one C6-C8 α-olefin comonomer. ULDPE and VLDPE have densities of 0.885 g / cc or 0.90 g / cc to 0.915 g / cc, respectively. Non-limiting examples of ULDPE and VLDPE include ATTANE™ ultra-low density polyethylene resin (available from The Dow Chemical Company) and FLEXOMER™ ultra-low density polyethylene resin (available from The Dow Chemical Company). DETAILED DESCRIPTION OF THE INVENTION

[0036] The present disclosure provides a process for manufacturing a conductor jacket. In one embodiment, the process includes blending a broad molecular weight distribution (MWD) ethylene-based polymer having an I21 / I2 ratio of 55 to 85 with a narrow MWD ethylene-based polymer having an I21 / I2 ratio of 20 to 50. The process includes forming a blend component including 20% ​​to 45% by weight of the broad MWD ethylene-based polymer, 80% to 55% by weight of the narrow MWD ethylene-based polymer, and optional carbon black. The blend component has a density of 0.925 g / cc to 0.955 g / cc and an I21 / I2 ratio of 30 to 55. The process includes extruding the blend component onto a conductor at a velocity greater than 1.02 meters per second (m / s) (i.e., greater than 200 feet per minute (ft / min)). The process includes forming a conductor jacket having a surface smoothness of 30 μin to 80 μin.

[0037] The present disclosure provides another process for manufacturing a conductor jacket. In one embodiment, the process includes blending a broad molecular weight distribution (MWD) ethylene-based polymer having an I21 / I2 ratio of 55 to 85 with a narrow MWD ethylene-based polymer having an I21 / I2 ratio of 20 to 50. The process includes forming a blend component including 20% ​​to 70% by weight of the broad MWD ethylene-based polymer, 80% to 20% by weight of the narrow MWD ethylene-based polymer, and optionally, 0% to 10% by weight of carbon black. The blend component has a density of 0.925 g / cc to 0.955 g / cc and an I21 / I2 ratio of 15 to 65. The process includes extruding the blend component onto a conductor at a velocity greater than 1.02 meters per second (m / s) (i.e., greater than 200 feet per minute (ft / min)). The process includes forming a conductor jacket having a surface smoothness of 20 μin to 80 μin.

[0038] 1. Ethylene-based polymers with wide and narrow MWD. The process involves blending a broad MWD ethylene-based polymer with a narrow MWD ethylene-based polymer. A "broad molecular weight distribution ethylene-based polymer" or "broad MWD ethylene-based polymer" is an ethylene-based polymer having an I21 / I2 ratio of 55 to 85. A "narrow molecular weight distribution ethylene-based polymer" or "narrow MWD ethylene-based polymer" is an ethylene-based polymer having an I21 / I2 ratio of 20 to 50.

[0039] The ethylene-based polymer can be an ethylene homopolymer or an ethylene / α-olefin copolymer. Non-limiting examples of suitable α-olefin comonomers for ethylene-based polymers include C3-C 20 Alpha olefins, or C4-C 12 Examples of suitable α-olefin comonomers include α-olefins, C4-C8 α-olefins, or C4-C8 α-olefins. Further non-limiting examples of suitable α-olefin comonomers include propylene, butene, methyl-1-pentene, hexene, octene, decene, dodecene, tetradecene, hexadecene, octadecene, cyclohexyl-1-propene (allylcyclohexane), vinylcyclohexane, and combinations thereof. In one embodiment, the α-olefin comonomer for the ethylene-based polymer is selected from butene, hexene, or octene.

[0040] In one embodiment, the broad MWD ethylene-based elastomer is an ethylene / C4-C8 α-olefin copolymer having one, some, or all of the following properties:

[0041] (i) a density of 0.915 g / cc, or 0.920 g / cc, or 0.925 g / cc, or 0.930 g / cc, or 0.933 g / cc to 0.935 g / cc, or 0.937 g / cc; and / or

[0042] (ii) 0.5 g / 10 min, or 0.6 g / 10 min, or 0.65 g / 10 min, or 0.7 g / 10 min to 0.8 g / 10 min, or 0.9 g / 10 min I2, and / or

[0043] (iii) 35g / 10min, or 40g / 10min, or 45g / 10min, or 50g / 10min to 55g / 10min, or 60g / 10min, or 65g / 10min, or 70g / 10min, or 75g / 10min I21, and / or

[0044] (iv) I21 / I2 of 55, or 60, or 65-70, or 75, or 80, or 85.

[0045] In one embodiment, the broad MWD ethylene-based polymer is an ethylene / C4-C8 α-olefin copolymer that is a medium density polyethylene or "broad MWD MDPE." Broad MDPE has one, some, or all of the following properties:

[0046] (i) a density of 0.933 g / cc, or 0.935 g / cc to 0.937 g / cc, and / or

[0047] (ii) 0.5 g / 10 min, or 0.65 g / 10 min, or 0.8 g / 10 min to 1.0 g / 10 min, or 1.5 g / 10 min of I2; and / or

[0048] (iii) I21 of 45 g / 10 min, or 49 g / 10 min, or 50 g / 10 min to 52 g / 10 min, or 54 g / 10 min, or 55 g / 10 min, and / or

[0049] (iv) I21 / I2 of 60, or 65, or 70-75, or 80.

[0050] In one embodiment, the broad MWD ethylene-based polymer is an ethylene / C4-C8 α-olefin copolymer that is a linear low density polyethylene or "broad MWD LLDPE." A broad LLDPE has one, some, or all of the following properties:

[0051] (i) a density of 0.915 g / cc, or 0.920 g / cc to 0.925 g / cc, and / or

[0052] (ii) 0.5 g / 10 min, or 0.65 g / 10 min, or 0.8 g / 10 min to 1.0 g / 10 min, or 1.5 g / 10 min of I2; and / or

[0053] (iii) I21 of 45 g / 10 min, or 49 g / 10 min, or 50 g / 10 min to 52 g / 10 min, or 54 g / 10 min, or 55 g / 10 min, and / or

[0054] (iv) I21 / I2 of 60, or 65, or 70-75, or 80.

[0055] In one embodiment, the narrow MWD ethylene-based polymer is an ethylene / C4-C8 α-olefin copolymer that is a linear low density polyethylene or "narrow MWD LLDPE." A narrow MWD LLDPE has one, some, or all of the following properties:

[0056] (i) a density of 0.915 g / cc, or 0.917 g / cc, or 0.918 g / cc to 0.919 g / cc;

[0057] (ii) 0.5 g / 10 min, 0.9 g / 10 min, 1.0 g / 10 min, or 1.5 g / 10 min, 2.0 g / 10 min to 2.3 g / 10 min, or 2.5 g / 10 min, or 2.9 g / 10 min, or 3.0 g / 10 min I2, and / or

[0058] (iii) 35g / 10min, or 40g / 10min, or 50g / 10min, or 60g / 10min, or 61g / 10min to 70g / 10min, or 71g / 10min, or 80g / 10min, or 85g / 10min, or 87g / 10min, or 90g / 10min I21, and / or

[0059] (iv) I21 / I2 ratio of 20, or 25, or 27, or 30, or 31-35, or 39, or 40, or 45, or 50.

[0060] In one embodiment, the narrow MWD ethylene-based polymer is an ethylene / C4-C8 α-olefin copolymer that is a medium density polyethylene or "MDPE." A narrow MWD MDPE has one, some, or all of the following properties:

[0061] (i) a density of 0.933 g / cc, or 0.935 g / cc to 0.937 g / cc, and / or

[0062] (ii) 2.2 g / 10 min, or 2.3 g / 10 min, or 2.5 g / 10 min to 2.8 g / 10 min I2, and / or

[0063] (iii) 30 g / 10 min, or 33 g / 10 min to 35 g / 10 min, or 37 g / 10 min, or 40 g / 10 min I21, and / or

[0064] (iv) I21 / I2 of 25, or 27, or 28, or 30~.

[0065] 2. Blending ingredients The process involves blending a broad MWD ethylene-based polymer and a narrow MWD ethylene-based polymer to form a blend component. In one embodiment, the blending is accomplished by melt blending. "Melt blending" is a process by which at least two components are combined or otherwise mixed together, with at least one of the components being in a molten state. Melt blending can be accomplished by batch mixing, extrusion blending, extrusion molding, and any combination thereof.

[0066] In one embodiment, the blend components include 20 wt%, or 25 wt%, or 30 wt% to 30 wt%, or 35 wt%, or 40 wt%, or 45 wt% broad MWD ethylene-based polymer and 80 wt%, or 75 wt%, or 79 wt% to 65 wt%, or 60 wt%, or 55 wt% narrow MWD ethylene-based polymer. The blend components also include 1 wt%, or 2 wt%, or 3 wt%, or 5 wt% to 7 wt%, or 9 wt%, or 10 wt% carbon black. A non-limiting example of a suitable carbon black is DFNA-0037BK. The blend components have a density of 0.925 g / cc, or 0.930 g / cc, or 0.935 g / cc, or 0.940 g / cc to 0.945 g / cc, or 0.950 g / cc, or 0.955 g / cc, and an I21 / I2 ratio of 30, or 32, or 34, or 36, or 38, or 40, or 42, or 45 to 46, or 48, or 50, or 52, or 55.

[0067] In another embodiment, the blend components include 20 wt%, or 25 wt%, or 30 wt%, or 30 wt%, or 35 wt%, or 40 wt%, or 45 wt% to 50 wt%, or 55 wt%, or 60 wt%, or 65 wt%, or 70 wt% broad MWD ethylene-based polymer and 80 wt%, or 75 wt%, or 79 wt%, or 65 wt%, or 60 wt%, or 55 wt%, or 50 wt%, or 49 wt%, or 45 wt% to 40 wt%, or 35 wt%, or 30 wt%, or 25 wt%, or 20 wt% narrow MWD ethylene-based polymer. The blend components have a density of 0.925 g / cc, or 0.930 g / cc, or 0.933 g / cc, or 0.935 g / cc, or 0.940 g / cc to 0.945 g / cc, or 0.948 g / cc, or 0.950 g / cc, or 0.955 g / cc, and an I21 / I2 ratio of 15, or 17, or 20, or 30, or 32, or 34, or 36, or 38, or 40, or 45 to 50, or 52, or 55, or 60, or 62, or 65.

[0068] In another embodiment, the blend components include 20 wt%, or 25 wt%, or 30 wt%, or 30 wt%, or 35 wt%, or 40 wt%, or 45 wt% to 50 wt%, or 55 wt%, or 60 wt%, or 65 wt%, or 70 wt% broad MWD ethylene-based polymer, 80 wt%, or 75 wt%, or 79 wt%, or 65 wt%, or 60 wt%, or 55 wt%, or 50 wt%, or 49 wt%, or 45 wt% to 40 wt%, or 35 wt%, or 30 wt%, or 25 wt%, or 20 wt% narrow MWD ethylene-based polymer, and 1 wt%, or 2 wt%, or 3 wt%, or 5 wt% to 7 wt%, or 9 wt%, or 10 wt% carbon black. The individual weight percentages of the broad MWD ethylene-based polymer, narrow MWD ethylene-based polymer, and carbon black are considered to add up to 100 weight percent of the blend components (including any additives). The blend components have a density of 0.925 g / cc, or 0.930 g / cc, or 0.933 g / cc, or 0.935 g / cc, or 0.940 g / cc to 0.945 g / cc, or 0.948 g / cc, or 0.950 g / cc, or 0.955 g / cc, and an I21 / I2 ratio of 15, or 17, or 20, or 30, or 32, or 34, or 36, or 38, or 40, or 45 to 50, or 52, or 55, or 60, or 62, or 65.

[0069] The blend components may include one or more optional additives. Non-limiting examples of suitable additives include antioxidants, colorants, ultraviolet (UV) absorbers or stabilizers, antiblocking agents, flame retardants, compatibilizers, plasticizers, fillers, processing aids, and combinations thereof.

[0070] In one embodiment, the blend component includes an antioxidant. Non-limiting examples of suitable antioxidants include phenolic antioxidants, thio antioxidants, phosphate antioxidants, and hydrazine metal deactivators. In a further embodiment, the blend component includes an antioxidant such as IRGANOX 1035 present in an amount of 0.1 wt %, or 0.2 wt % to 0.3 wt %, based on the total weight of the blend component.

[0071] In one embodiment, the blend components include a filler. Non-limiting examples of suitable fillers include zinc oxide, zinc borate, zinc molybdate, zinc sulfide, organoclay, and combinations thereof. The filler may or may not have flame retardant properties.

[0072] In one embodiment, the blend components include a processing aid. Non-limiting examples of suitable processing aids include oils, organic acids (such as stearic acid), and metal salts of organic acids (such as zinc stearate). In a further embodiment, the blend components include a processing aid such as DYNAMAR FX 5912, present in an amount of 0.01 wt.%, or 0.05 wt.%, or 0.1 wt.% to 0.15 wt.%, or 0.17 wt.%, or 0.2 wt.%, based on the total weight of the blend components.

[0073] In one embodiment, the blend components include 20% to 45% by weight of a broad MWD ethylene-based polymer, 80% to 55% by weight of a narrow MWD ethylene-based polymer, and 1% to 10% by weight of carbon black, where the broad MWD ethylene-based polymer, narrow ethylene-based polymer, and carbon black total 100% by weight of the blend components (including any additives). The blend components have a density of 0.925 g / cc, or 0.930 g / cc, or 0.935 g / cc to 0.940 g / cc, or 0.950 g / cc, or 0.955 g / cc, and an I21 / I2 ratio of 30, or 34 to 37, or 40, or 43, or 45, or 47, or 49, or 50, or 52, or 55.

[0074] In one embodiment, the blend components include 20 wt% to 45 wt%, or 55 wt%, or 70 wt% broad MWD ethylene-based polymer, 80 wt% to 55 wt%, or 49 wt%, or 45 wt%, or 30 wt%, or 25 wt%, or 20 wt% narrow MWD ethylene-based polymer, and 0 wt%, or 1 wt% to 10 wt% carbon black, where the broad MWD ethylene-based polymer, narrow ethylene-based polymer, and carbon black total 100 wt% of the blend components (including any additives). The blend components have a density of 0.925 g / cc, or 0.930 g / cc, or 0.933 g / cc, or 0.935 g / cc, or 0.940 g / cc to 0.945 g / cc, or 0.948 g / cc, or 0.950 g / cc, or 0.955 g / cc, and an I21 / I2 ratio of 15, or 17, or 20, or 30, or 32, or 34, or 36, or 38, or 40, or 45 to 50, or 52, or 55, or 60, or 62, or 65.

[0075] In one embodiment, the blend component is devoid of or otherwise free of propylene.

[0076] In one embodiment, the blend components are devoid of or otherwise free of high density ethylene or "HDPE."

[0077] 3. Extrusion The process involves extruding the blend components onto a conductor at a velocity of greater than 1.02 meters per second (m / s) (200 feet per minute (ft / min)) and forming a conductor jacket having a surface smoothness of 25 μin, or 30 μin, or 35 μin, or 40 μin, or 50 μin to 60 μin, or 70 μin, or 80 μin.

[0078] The extrusion process is carried out by an extruder. The extruder has a crosshead die, which provides the desired layer (wall or coating) thickness. Non-limiting examples of extruders that can be used include single-screw types modified with a crosshead die, a cooler, and a continuous take-up device. A typical single-screw extruder can be described as having a hopper at its upstream end and a die at its downstream end. The hopper feeds into a barrel containing a screw. At the downstream end, between the end of the screw and the die, there is a screen pack and a breaker plate. The screw section of the extruder can be considered divided into three sections: a feed section, a compression section, and a metering section, as well as multiple heating zones from a rear heating zone to a front heating zone, with multiple sections extending from upstream to downstream. The barrel length-to-diameter ratio ranges from 16:1 to 30:1. Grooved barrel extruders or twin-screw extruders can also be used in the core coating process. The jacket extrusion process can be carried out at temperatures ranging from 160°C, 180°C, 200°C to 220°C, 240°C, or 260°C. The crosshead die distributes the blend components into flow channels so that they exit at a uniform rate and are applied to the conductor. In this way, blending (melt blending) and extrusion occur in the same single extruder. The conductor passes through the center of the crosshead, and as it exits, a uniform layer of blend components is applied circumferentially using either tube-on-tool pressure or semi-pressure. One or more layers of blend components (or other materials) can be applied using multiple crossheads. The coated conductor is then cooled sufficiently in a water trough to prevent deformation of the applied blend component layer on the take-up reel and to obtain the conductor jacket.

[0079] Melt blending may occur sequentially prior to extrusion. Alternatively, melt blending may occur simultaneously or substantially simultaneously with extrusion (i.e., melt blending and extrusion occur in the same extruder). Carbon black may be added during melt blending and / or extrusion.

[0080] The extrusion speed is greater than 1.02 m / s (>200 ft / min). In one embodiment, the extrusion speed is greater than 1.02 m / s, or 1.14 m / s, or 1.27 m / s, or 1.40 m / s to 1.52 m / s, or 1.65 m / s.

[0081] The process includes forming a conductor jacket, the conductor jacket being comprised of the blend components, the conductor jacket having a surface smoothness of 25 microinches, or 30 microinches, or 35 microinches, or 40 microinches, or 50 microinches to 60 microinches, or 70 microinches, or 80 microinches.

[0082] In one embodiment, a cable jacket comprised of the blend components has a thickness of about 0.508 mm, or 0.762 mm, or 1.016 mm, or 1.27 mm to 1.524 mm, or 1.778 mm, or 2.032 mm, or 2.286 mm, or 2.54 mm, and an extrusion speed of greater than 1.02 m / s, or 1.14 m / s, or 1.27 m / s to 1.40 m / s, or 1.52 m / s, or 1.65 m / s. In a further embodiment, the conductor jacket is devoid of propylene-based polymer and / or HDPE.

[0083] In one embodiment, the process comprises blending a broad MWD linear low density polyethylene (LLDPE) having a density of 0.915 g / cc, or 0.920 g / cc to 0.925 g / cc, and an I21 / I2 ratio of 73, or 75 to 77, with a narrow MWD LLDPE having a density of 0.915 g / cc, or 0.920 g / cc to 0.924 g / cc, and an I21 / I2 ratio of 30, or 33 to 35. The process includes forming a blend component containing 20%, 25%, 30%, 35% to 40%, or 45% by weight of a wide MWD LLDPE, 70%, 65%, 60% to 55%, or 50% by weight of a narrow MWD LLDPE, and 1%, 2%, 3%, 4% to 5%, 6%, or 7% by weight of carbon black. The blend component has a density of less than 0.925 g / cc, 0.930 g / cc to 0.935 g / cc, and an I21 / I2 ratio of 30, 35, 40, 45 to 50, or 55. The process includes extruding the blend components onto a conductor at a velocity greater than 1.02 m / sec (or 1.52 m / sec) and forming a conductor jacket having a surface smoothness of 30 μin, or 40 μin, or 50 μin to 60 μin, or 70 μin, or 80 μin.

[0084] In one embodiment, the process comprises blending a broad MWD linear low density polyethylene (LLDPE) having a density of 0.915 g / cc, or 0.920 g / cc to 0.925 g / cc, and an I21 / I2 ratio of 73, or 75 to 77, with a narrow MWD LLDPE having a density of 0.915 g / cc, or 0.920 g / cc to 0.924 g / cc, and an I21 / I2 ratio of 20, or 24, or 30, or 33 to 35. The process includes forming a blend component that includes 20 wt%, or 25 wt%, or 30 wt%, or 35 wt% to 40 wt%, or 45 wt%, or 50 wt%, or 55 wt%, or 60 wt%, or 65 wt%, or 70 wt% wide MWD LLDPE, 70 wt%, or 65 wt%, or 60 wt% to 55 wt%, or 50 wt%, or 49 wt%, or 45 wt%, or 40 wt%, or 35 wt%, or 30 wt%, or 25 wt%, or 20 wt% narrow MWD LLDPE, and 1 wt%, or 2 wt%, or 3 wt%, or 4 wt% to 5 wt%, or 6 wt%, or 7 wt% carbon black. The blend components have a density of 0.925 g / cc, or 0.930 g / cc, or 0.933 g / cc to 0.935 g / cc, or 0.940 g / cc, or 0.945 g / cc, or 0.948 g / cc, or 0.950 g / cc, or 0.955 g / cc, and an I21 / I2 ratio of 30, or 32, or 34, or 36, or 38, or 40, or 45 to 50, or 52, or 55, or 60, or 62, or 65. The process includes extruding the blend components onto a conductor at a speed greater than 1.02 m / sec (or 1.52 m / sec) and forming a conductor jacket having a surface smoothness of 30 microinches, or 40 microinches, or 50 microinches to 60 microinches, or 70 microinches, or 80 microinches.

[0085] In one embodiment, the process comprises blending a broad MWD linear low density polyethylene (LLDPE) having a density of 0.915 g / cc, or 0.920 g / cc to 0.925 g / cc, and an I21 / I2 ratio of 73, or 75 to 77, with a narrow MWD LLDPE having a density of 0.915 g / cc, or 0.917 g / cc to 0.920 g / cc, and an I21 / I2 ratio of 30, or 31 to 33. The process includes forming a blend component containing 23%, 25%, 30%, 35% to 40%, or 45% by weight of a wide MWD LLDPE, 70%, 65%, 60% to 55%, or 50% by weight of a narrow MWD LLDPE, and 1%, 2%, 3%, 4% to 5%, 6%, or 7% by weight of carbon black. The blend component has a density of less than 0.925 g / cc, 0.930 g / cc to 0.935 g / cc, and an I21 / I2 ratio of 33, 35, 37 to 39, 40, or 42. The process involves extruding the blend components onto a conductor at a velocity greater than 1.02 m / sec (or 1.52 m / sec) and forming a conductor jacket having a surface smoothness of 45 μin, or 50 μin, or 55 μin, or 60 μin, or 65 μin to 70 μin, or 75 μin, or 80 μin (hereinafter Process A).

[0086] In one embodiment, Process A includes forming a conductor jacket having a tensile strength of 20.0 MPa, or between 21 MPa and 22.0 MPa, and a tensile elongation of 825%, or between 850%, or between 870% and 900%, or between 910%.

[0087] In one embodiment, the process comprises blending a broad MWD linear low density polyethylene (LLDPE) having a density of 0.915 g / cc, or 0.920 g / cc to 0.925 g / cc, and an I21 / I2 ratio of 73, or 75 to 77, with a narrow MWD LLDPE having a density of 0.915 g / cc, or 0.917 g / cc to 0.920 g / cc, and an I21 / I2 ratio of 30, or 31 to 33. The process includes forming a blend component containing 23%, 25%, 30%, 35% to 40%, or 45% wide MWD LLDPE, 70%, 65%, 60% to 55%, or 50% narrow MWD LLDPE, and 1%, 2%, 3%, 4% to 5%, 6%, or 7% carbon black. The blend component has a density of less than 0.925 g / cc, 0.930 g / cc to 0.935 g / cc, and an I21 / I2 ratio of 35, 40, 45, 50, or 55. This process involves extruding the blend components onto a conductor at a velocity greater than 1.02 m / sec (or 1.52 m / sec) and forming a conductor jacket having a surface smoothness of 35 μin, or 40 μin to 45 μin, or 50 μin (hereinafter Process B).

[0088] In one embodiment, Process B includes forming a conductor jacket having a tensile strength of 19.0 MPa, or 20.0 MPa to 21.0 MPa, or 23.0 MPa, and a tensile elongation of 780%, or 800% to 820%, or 850%, or 870%.

[0089] In one embodiment, the process comprises blending a broad MWD medium density polyethylene (MDPE) having a density from 0.933 g / cc, or 0.935 g / cc to less than 0.937 g / cc, and an I21 / I2 ratio of 55, or 60, or 65 to 70, or 75, with a narrow MWD ethylene-based polymer having a density from 0.920 g / cc, or 0.925 g / cc to 0.930 g / cc, or 0.935 g / cc, and an I21 / I2 ratio of 25, or 30 to 35, or 40. The process includes forming a blend component containing 35%, 40%, to 50%, or 55% by weight of a wide MWD MDPE, 50%, 45%, to 40% by weight of a narrow MWD ethylene-based polymer, and 1%, 2%, 3%, 4%, to 5%, 6%, or 7% by weight of carbon black. The blend component has a density of less than 0.935 g / cc, or 0.940 g / cc to 0.945 g / cc, and an I21 / I2 ratio of 35, or 40, to 50, or 55. The process includes extruding the blend component onto a conductor at a velocity greater than 1.02 m / s (or 1.52 m / s) and forming a conductor jacket having a surface smoothness of 40 μin, or 45 μin, or 50 μin to 55 μin, or 60 μin (hereinafter, Process C).

[0090] In one embodiment, Process C includes forming a conductor jacket having a tensile strength of 27 MPa, or between 29 MPa and 30 MPa, and a tensile elongation of 830%, or 850%, or 880%, 900% to 920%, or 950%, or 970%.

[0091] In one embodiment, the process involves blending a broad MWD medium density polyethylene (MDPE) having a density of 0.933 g / cc, or 0.935 g / cc to 0.937 g / cc, and an I21 / I2 ratio of 63, or 65 to 67, with a narrow MWD MDPE having a density of 0.933 g / cc, or 0.935 g / cc to 0.937 g / cc, and an I21 / I2 ratio of 25, or 27 to 30. The process involves forming a blend component that includes 35 wt%, or 40 wt% to 45 wt%, or 50 wt% of the broad MWD MDPE, 65 wt%, or 60 wt%, or 55 wt% to 50 wt%, or 45 wt% of the narrow MDPE, and 1 wt%, or 2 wt%, or 3 wt%, or 4 wt% to 5 wt%, or 6 wt%, or 7 wt% carbon black. The blend components have a density of 0.935 g / cc, or 0.937 g / cc, or 0.940 g / cc to less than 0.945 g / cc, and an I21 / I2 of 40, or 43 to 45. The process includes extruding the blend components onto a conductor at a speed greater than 1.02 m / sec (or 1.52 m / sec) and forming a conductor jacket having a surface smoothness of 50 μin, or 55 μin to 60 μin (hereinafter Process D).

[0092] In one embodiment, Process D includes forming a conductor jacket having a tensile strength of 27 MPa, or between 29 MPa and 30 MPa, and a tensile elongation of 860%, or 880%, or 900% to 920%, or 950%, or 970%.

[0093] In one embodiment, the process comprises blending a broad MWD linear low density polyethylene (LLDPE) having a density of 0.915 g / cc, or 0.920 g / cc to 0.925 g / cc, and an I21 / I2 ratio of 73, or 75 to 77, with a narrow MWD LLDPE having a density of 0.915 g / cc, or 0.917 g / cc to 0.920 g / cc, and an I21 / I2 ratio of 20, or 24 to 25, or 30, or 35. The process includes forming a blend component that includes 30 wt%, or 35 wt%, or 40 wt%, or 45 wt%, or 50 wt%, or 55 wt% to 60 wt%, or 65 wt%, or 70 wt% wide MWD LLDPE, 70 wt%, or 65 wt%, or 60 wt%, or 55 wt%, or 50 wt%, or 49 wt%, or 45 wt% to 40 wt%, or 35 wt%, or 30 wt%, or 25 wt%, or 20 wt% narrow MWD LLDPE, and 1 wt%, or 2 wt%, or 3 wt%, or 4 wt% to 5 wt%, or 6 wt%, or 7 wt% carbon black. The blend components have a density of 0.925 g / cc, or 0.930 g / cc to 0.933 g / cc, or 0.934 g / cc, and an I21 / I2 ratio of 35, or 40, or 43 to 58, or 60, or 65. The process includes extruding the blend components onto a conductor at a speed greater than 1.02 m / sec (or 1.52 m / sec) and forming a conductor jacket having a surface smoothness of 45 μin, or 50 μin, or 55 μin, 60 μin, or 65 μin to 70 μin, or 75 μin, or 80 μin (hereinafter Process E).

[0094] In one embodiment, Process E includes forming a conductor jacket having a tensile strength of 15.0 MPa, or 16.0 MPa, or 16.2 MPa to 18.0 MPa, or 20.0 MPa, or 25.0 MPa, and a tensile elongation of 625%, or 650%, or 651% to 665%, or 670%, or 680%, or 700%.

[0095] In one embodiment, the process involves blending a medium density polyethylene (MDPE) having a broad MWD with a density of 0.933 g / cc, or 0.935 g / cc to 0.937 g / cc, and an I21 / I2 ratio of 63, or 65 to 67, with a narrow MWD MDPE having a density of 0.933 g / cc, or 0.935 g / cc to 0.937 g / cc, and an I21 / I2 ratio of 25, or 27 to 30. The process includes forming a blend component that includes 35 wt%, or 40 wt%, or 45 wt%, or 50 wt% to 55 wt%, or 60 wt%, or 65 wt%, or 70 wt% wide MWD MDPE, 65 wt%, or 60 wt%, or 55 wt%, or 50 wt%, or 49 wt% to 45 wt%, or 40 wt%, or 35 wt%, or 30 wt%, or 25 wt%, or 20 wt% narrow MDPE, and 1 wt%, or 2 wt%, or 3 wt%, or 4 wt% to 5 wt%, or 6 wt%, or 7 wt% carbon black. The blend components have a density of 0.935 g / cc, or 0.937 g / cc, or 0.940 g / cc to 0.945 g / cc, or 0.950 g / cc, and an I21 / I2 of 15, or 17 to 18, or 20, or 25, or 30, or 35. The process includes extruding the blend components onto a conductor at a speed greater than 1.02 m / sec (or 1.52 m / sec) and forming a conductor jacket having a surface smoothness of 20 μin, or 25 μin to 30 μin, or 40 μin (hereinafter Process F).

[0096] In one embodiment, Process F includes forming a conductor jacket having a tensile strength of 25 MPa, or 26 MPa, or 27 MPa, or 29 MPa to 30 MPa, and a tensile elongation of 800%, or 807% to 810%, or 820%, or 860%, or 880%, or 900%.

[0097] In one embodiment, the process comprises blending a broad MWD medium density polyethylene (MDPE) having a density of 0.933 g / cc, or 0.935 g / cc to 0.937 g / cc, and an I21 / I2 ratio of 63, or 65 to 67, with a narrow MWD LLDPE having a density of 0.915 g / cc, or 0.917 g / cc to 0.920 g / cc, or 0.921 g / cc, or 0.925 g / cc, and an I21 / I2 ratio of 30, or 31 to 33, or 39, or 40. The process includes forming a blend component that includes 35 wt%, or 40 wt%, or 45 wt%, or 50 wt% to 55 wt%, or 60 wt%, or 65 wt%, or 70 wt% wide MWD MDPE, 65 wt%, or 60 wt%, or 55 wt%, or 50 wt%, or 49 wt% to 45 wt%, or 40 wt%, or 35 wt%, or 30 wt%, or 25 wt%, or 20 wt% narrow LLDPE, and 1 wt%, or 2 wt%, or 3 wt%, or 4 wt% to 5 wt%, or 6 wt%, or 7 wt% carbon black. The blend components have a density of 0.935 g / cc, or 0.937 g / cc, or 0.940 g / cc to 0.945 g / cc, or 0.948 g / cc, or 0.950 g / cc, and an I21 / I2 of 30, or 40, or 50, or 55, or 60 to 62, or 65. The process includes extruding the blend components onto a conductor at a speed greater than 1.02 m / sec (or 1.52 m / sec) and forming a conductor jacket having a surface smoothness of 20 μin, or 25 μin to 30 μin, or 40 μin (hereinafter Process G).

[0098] In one embodiment, Process G includes forming a conductor jacket having a tensile strength of 25 MPa, or 26 MPa, or 27 MPa, or 29 MPa to 30 MPa, and a tensile elongation of 800%, or 805% to 810%, or 820%, or 860%, or 880%, or 900%.

[0099] The present process, utilizing two polymer blend components, advantageously provides improved processability (i.e., the ability to be extruded at line speeds greater than 1.02 m / s) while simultaneously achieving acceptable surface smoothness (30-80 μin) for the conductor jacket and improving the tensile strength and tensile elongation of the jacket.

[0100] A surface smoothness of 20-80 microns provides aesthetic value and customer satisfaction. The process, utilizing two polymer blend components, minimizes diameter variations in the conductor jacket. A smoothness of 20-80 microns, or 30-80 microns, minimizes defects at internal interfaces.

[0101] By way of example, and not limitation, examples of the present disclosure are provided. [Example]

[0102] The materials used in the examples and comparative examples of the present invention are shown in Table 1A below.

[0103] [Table 1A-1]

[0104] [Table 1A-2]

[0105] CS1-9 and IE1-12 Melt Blending Process A Banbury mixer / melt-fed pelletizing extruder compounding line is used to produce blends of CS1-9 and IE1-12. The Banbury system typically provides very good control of compounding temperatures. A three-stage mixing cycle with a 175°C drop temperature is used.

[0106] Extrusion Insulated wire extrusion tests CS1-9 and IE1-12 are completed on a 6.35 cm (2.5 in) Davis Standard wireline. The 6.35 cm Davis Standard wire and cable extruder is equipped with a 24:1 L / D barrel. The extruder is configured with a polyethylene-type Maddox mixing head screw with a 3:1 compression ratio. The extruder discharge flows through a 9 / 32 in. x 5 / 8 in. Guill die in an adjustable central crosshead and through a specialized tubing tip and coating die to form a melt stream for sample extrusion. This equipment is used to produce samples with a final diameter of approximately 2.9 mm (0.114 in.) and a wall thickness of approximately 0.635 mm (0.025 in.) on 14 American Wire Gauge (AWG) solid copper conductors (1.63 mm / 0.064 in. diameter).

[0107] CS10-15 and IE13-16 Melt Blending Process Before preparing the wire samples, CS10-15 and IE13-16 were first mixed in a laboratory-scale Brabender mixer. A 250cc Brabender mixing bowl and cam-type mixing blade were used to melt-mix the samples. The mixer temperature was set to 180°C. The mixing process involved first adding the resin to the mixing bowl at a mixing speed of 15 revolutions per minute (rpm). Both heating zones were set to 180°C. After the resin began to melt, carbon black masterbatch (DFNA-0037BK), processing aid (Dynamar FX 5912), and antioxidant (Irganox 1035) were added and mixed at 50 rpm for 6 minutes. The molten material was then removed, placed between Mylar sheets, and pressed into sheets at room temperature (23°C) using a Wabash compression molding press. A Berlyn pelletizer was used to pelletize the samples.

[0108] Mini Wire Extrusion Coated wire extrusions are performed for each material onto 14-gauge copper wire using a Brabender Mini-Wire line. The machine settings are shown in Table 1B. This equipment is used to produce samples with a final diameter of approximately 0.086 inches and a wall thickness of approximately 0.01 inches onto 1.63 mm (0.064 inch) diameter 14 AWG solid copper conductors. After extrusion, the surface smoothness is measured with a profilometer.

[0109] [Table 1B]

[0110] The properties of the comparative conductor sheath samples and examples of the present invention are shown in Tables 2-4 below.

[0111] Qualitative smoothness is determined visually. In Tables 2-4, a qualitative smoothness of "++" indicates a very smooth wire surface. A qualitative smoothness of "--" indicates a very rough wire surface.

[0112] [Table 2]

[0113] [Table 3]

[0114] [Table 4]

[0115] Tables 2-4 show that components with different I21 / I2 viscosity profiles can be blended to meet and / or exceed conventional conductor jacket compound specification targets, particularly with respect to final I21 / I2, melt index, density, mechanical properties, environmental stress cracking, and surface smoothness.

[0116] The present disclosure advantageously expands the range of base resins suitable for forming conductor jackets having surface smoothness of 20-80 microinches at high speeds (ie, extrusions greater than 1.02 m / sec).

[0117] The extrusion properties of Examples 1-15 of the present invention demonstrate unexpected extrusion behavior. Polyethylene resins with broad MWDs and long chain branching are known to exhibit excellent processability, i.e., such polyethylenes can be extruded at high line speeds with excellent surface smoothness. In contrast, polyethylene resins with narrow MWDs exhibit viscosity profiles that are relatively lacking in both melt strength and shear thinning behavior. Thus, narrow MWD polyethylene polymers have limited extrusion performance and typically result in conductor jackets with poor surface smoothness (i.e., surface smoothness greater than 80 μin) when processed at speeds greater than 1.02 m / s.

[0118] The blend components of the present invention surprisingly retain good surface smoothness (20-80 μin) even at high content levels of narrow MWD polyethylene (up to 70 wt%). It is unexpected that surface smoothness improves with the addition of narrow MWD polyethylene, i.e., the surface smoothness is not a linear function of narrow MWD polyethylene weight percent content, as shown by the data in Tables 2, 3, and 4. Furthermore, the blend components of the present invention as a whole exhibit improved mechanical properties across the proposed composition range.

[0119] The present disclosure is not limited to the embodiments and figures contained herein, but is specifically intended to include modifications of these embodiments, such as portions of the embodiments and combinations of elements of different embodiments that fall within the scope of the following claims. The present application also relates to the following aspects: (1) A manufacturing process for a conductor jacket, comprising: 55~85 I 21 / I 2 Broad molecular weight distribution (MWD) ethylene polymers with a ratio of 20 to 50 21 / I 2 a narrow MWD ethylene-based polymer having a ratio of 0.1 to 0.5; forming a blend component comprising 20 wt% to 45 wt% of the broad MWD ethylene-based polymer, 80 wt% to 55 wt% of the narrow MWD ethylene-based polymer, and optional carbon black, wherein the blend component has a density of 0.925 g / cc to 0.955 g / cc and an I of 30 to 55; 21 / I 2 forming a ratio of extruding the blend components onto a conductor at a velocity greater than 1.02 m / sec; forming a conductor jacket having a surface smoothness of between 30 microns and 80 microns. (2) Density of 0.915g / cc to 0.925g / cc and I of 73 to 77 21 / I 2 Linear low density polyethylene (LLDPE) with a wide MWD range and a density of 0.915g / cc to 0.925g / cc and an I of 30 to 35. 21 / I 2 and blending a narrow MWD LLDPE having a ratio of forming a blend component comprising 20 wt% to 45 wt% of said broad MWD LLDPE, 70 wt% to 50 wt% of said narrow MWD LLDPE, and 1 wt% to 10 wt% carbon black, said blend component having a density of 0.925 g / cc to less than 0.935 g / cc and an I of 30 to 55; 21 / I 2 forming a ratio of extruding the blend components onto the conductor at a velocity greater than 1.02 m / sec; and forming a conductive jacket having a surface smoothness of 30 μ inches to 80 μ inches. (3) Density of 0.915g / cc to 0.925g / cc and I of 73 to 77 21 / I 2 Linear low density polyethylene (LLDPE) with a wide MWD range and a density of 0.915 g / cc to 0.920 g / cc, and an I of 30 to 33. 21 / I 2 and blending a narrow MWD LLDPE having a ratio of forming a blend component comprising 23 wt% to 45 wt% of said broad MWD LLDPE, 70 wt% to 50 wt% of said narrow MWD LLDPE, and 1 wt% to 7 wt% carbon black, said blend component having a density of 0.925 g / cc to less than 0.935 g / cc and an I of 33 to 42; 21 / I 2 forming a ratio of extruding the blend components onto the conductor at a velocity greater than 1.02 m / sec; and forming a conductive jacket having a surface smoothness of 45 μ inches to 80 μ inches. (4) The process according to (3), comprising forming a conductor jacket having a tensile strength of 20.0 MPa to 22.0 MPa and a tensile elongation of 825% to 910%. (5) Density of 0.915g / cc to 0.925g / cc and I of 73 to 77 21 / I 2 Linear low density polyethylene (LLDPE) with a wide MWD range and a density of 0.915 g / cc to 0.920 g / cc, and an I of 30 to 33. 21 / I 2 and blending a narrow MWD LLDPE having a ratio of forming a blend component comprising 23 wt% to 45 wt% of said broad MWD LLDPE, 70 wt% to 50 wt% of said narrow MWD LLDPE, and 1 wt% to 7 wt% carbon black, said blend component having a density of less than 0.925 g / cc to 0.935 g / cc and an I of 35 to 55; 21 / I 2 forming a extruding the blend components onto the conductor at a velocity greater than 1.02 m / sec; and forming a conductive jacket having a surface smoothness of 35 μ inches to 50 μ inches. (6) The process according to (5) above, which includes forming a conductor jacket having a tensile strength of 19.0 MPa to 23.0 MPa and a tensile elongation of 780% to 870%. (7) Density less than 0.933g / cc to 0.937g / cc and I of 55 to 75 21 / I 2 Medium density polyethylene (MDPE) with a wide MWD, density from 0.920g / cc to 0.935g / cc, and I 21 / I 2 a narrow MWD ethylene-based polymer having a ratio of 0.1 to 0.5; forming a blend component comprising 35 wt% to 55 wt% of the broad MWD LLDPE, 50 wt% to 40 wt% of the narrow MWD ethylene-based polymer, and 1 wt% to 7 wt% carbon black, wherein the blend component has a density of 0.935 g / cc to less than 0.945 g / cc and an I 21 / I 2 forming a extruding the blend components onto the conductor at a velocity greater than 1.02 m / sec; and forming a conductive jacket having a surface smoothness of 40 μ inches to 60 μ inches. (8) The process according to (7), comprising forming a conductor jacket having a tensile strength of 27 MPa to 30 MPa and a tensile elongation of 830% to 970%. (9) Density of 0.933g / cc~0.937g / cc and I of 63~67 21 / I 2 Medium density polyethylene (MDPE) with a wide MWD, density from 0.933g / cc to 0.937g / cc, and I 21 / I 2 and blending a narrow MWD MDPE having a ratio of forming a blend component comprising 35 wt% to 50 wt% of the broad MWD MDPE, 65 wt% to 45 wt% of the narrow MWD MDPE, and 1 wt% to 7 wt% carbon black, wherein the blend component has a density of less than 0.935 g / cc to 0.945 g / cc and an I of 40 to 45. 21 / I 2 forming a extruding the blend components onto the conductor at a velocity greater than 1.02 m / sec; and forming a conductive jacket having a surface smoothness of 50 μ inches to 60 μ inches. (10) The process according to (9), comprising forming a conductor jacket having a tensile strength of 27 MPa to 30 MPa and a tensile elongation of 860% to 970%. (11) A manufacturing process for a conductor sheath, comprising: 55~85 I 21 / I 2 Broad molecular weight distribution (MWD) ethylene polymers with a ratio of 20 to 50 21 / I 2 a narrow MWD ethylene-based polymer having a ratio of 0.1 to 0.5; forming a blend component comprising 20 wt% to 70 wt% of the broad MWD ethylene-based polymer, 80 wt% to 20 wt% of the narrow MWD ethylene-based polymer, and optional carbon black, wherein the blend component has a density between 0.925 g / cc and 0.955 g / cc and an I of 15 to 65; 21 / I 2 forming a ratio of extruding the blend components onto a conductor at a velocity greater than 1.02 m / sec; forming a conductor jacket having a surface smoothness of between 20 microns and 80 microns. (12) Density of 0.915g / cc~0.925g / cc and I of 73~77 21 / I 2 Linear low density polyethylene (LLDPE) with a wide MWD range and a density of 0.915g / cc to 0.925g / cc and an I of 20 to 35. 21 / I 2 and blending a narrow MWD LLDPE having a ratio of forming a blend component comprising 50 wt% to 70 wt% of said broad MWD LLDPE, 49 wt% to 20 wt% of said narrow MWD LLDPE, and 1 wt% to 10 wt% carbon black, said blend component having a density of less than 0.925 g / cc to 0.935 g / cc and an I of 30 to 60; 21 / I 2 forming a ratio of extruding the blend components onto the conductor at a velocity greater than 1.02 m / sec; and forming a conductive jacket having a surface smoothness of 30 μ inches to 80 μ inches. (13) Density less than 0.933g / cc to 0.937g / cc and I of 55 to 75 21 / I 2 Medium density polyethylene (MDPE) with a wide MWD, density from 0.935g / cc to 0.940g / cc, and I 21 / I 2 Blending with a medium density polyethylene (MDPE) having a narrow MWD ratio; forming a blend component comprising 50 wt% to 70 wt% of the broad MWD LLDPE, 49 wt% to 20 wt% of the narrow MWD ethylene-based polymer, and 1 wt% to 10 wt% carbon black, wherein the blend component has a density of 0.935 g / cc to 0.950 g / cc and an I of 15 to 50; 21 / I 2 forming a extruding the blend components onto the conductor at a velocity greater than 1.02 m / sec; and forming a conductive jacket having a surface smoothness of 20 μ inches to 60 μ inches. (14) Density less than 0.933g / cc to 0.937g / cc and I of 55 to 75 21 / I 2 Medium density polyethylene (MDPE) with a wide MWD, density from 0.915g / cc to 0.925g / cc, and I 21 / I 2 and blending a linear low density polyethylene (LLDPE) having a narrow MWD ratio; forming a blend component comprising 50 wt% to 70 wt% of the broad MWD LLDPE, 49 wt% to 20 wt% of the narrow MWD ethylene-based polymer, and 1 wt% to 10 wt% carbon black, wherein the blend component has a density of 0.935 g / cc to 0.950 g / cc and an I of 40 to 65; 21 / I 2 forming a extruding the blend components onto the conductor at a velocity greater than 1.02 m / sec; and forming a conductive jacket having a surface smoothness of 20 μ inches to 60 μ inches.

Claims

1. A process for manufacturing a conductor jacket, comprising: 55-85 I ２１ / I ２ a first ethylene-based polymer having an I ratio of 20 to 50; ２１ / I ２ a second ethylene-based polymer having a ratio of forming a blend component comprising 20% ​​to 45% by weight of the first ethylene-based polymer, 80% to 55% by weight of the second ethylene-based polymer, and optional carbon black; The blend components have a density of 0.925 g / cc to 0.955 g / cc and an I ２１ / I ２ extruding the blend components onto a conductor at a velocity greater than 1.02 m / sec; forming a conductor jacket having a surface smoothness of 30 μin to 80 μin (0.76 μm to 2.03 μm).

2. Density of 0.915 g / cc to 0.925 g / cc and I of 73 to 77 ２１ / I ２ a first linear low density polyethylene (LLDPE) having a ratio of 0.915 g / cc to 0.925 g / cc and an I of 30 to 35; ２１ / I ２ a second LLDPE having a ratio of forming a blend component comprising 20% ​​to 45% by weight of said first LLDPE, 70% to 55% by weight of said second LLDPE, and 1% to 10% by weight of carbon black; The blend components have a density of from 0.925 g / cc to less than 0.935 g / cc and an I of from 33 to 55. ２１ / I ２ forming a ratio of extruding the blend components onto the conductor at a velocity greater than 1.02 m / sec; forming a conductor jacket having a surface smoothness of 30 μin to 80 μin (0.76 μm to 2.03 μm).

3. Density of 0.915 g / cc to 0.925 g / cc and I of 73 to 77 ２１ / I ２ a first linear low density polyethylene (LLDPE) having a ratio of 0.915 g / cc to 0.920 g / cc and an I of 30 to 33; ２１ / I ２ a second LLDPE having a ratio of forming a blend component comprising 23% to 45% by weight of said first LLDPE, 70% to 55% by weight of said second LLDPE, and 1% to 7% by weight of carbon black, said blend component having a density of 0.925 g / cc to less than 0.935 g / cc and an I of 33 to 42; ２１ / I ２ forming a ratio of extruding the blend components onto the conductor at a velocity greater than 1.02 m / sec; forming a conductor jacket having a surface smoothness of 45 μin to 80 μin (1.14 μm to 2.03 μm).

4. 4. The process of claim 3, comprising forming a conductor jacket having a tensile strength of 20.0 MPa to 22.0 MPa and a tensile elongation of 825% to 910%.

5. Density of 0.915 g / cc to 0.925 g / cc and I of 73 to 77 ２１ / I ２ a first linear low density polyethylene (LLDPE) having a ratio of 0.915 g / cc to 0.920 g / cc and an I of 30 to 33; ２１ / I ２ a second LLDPE having a ratio of forming a blend component comprising 23% to 45% by weight of the first LLDPE, 70% to 55% by weight of the second LLDPE, and 1% to 7% by weight of carbon black, wherein the blend component has a density of 0.925 g / cc to less than 0.935 g / cc and an I of 35 to 55; ２１ / I ２ forming a extruding the blend components onto the conductor at a velocity greater than 1.02 m / sec; forming a conductor jacket having a surface smoothness of 35 μin to 50 μin (0.89 μm to 1.27 μm).

6. 6. The process of claim 5, comprising forming a conductor jacket having a tensile strength of 19.0 MPa to 23.0 MPa and a tensile elongation of 780% to 870%.

7. Density of 0.933 g / cc to less than 0.937 g / cc and I of 55 to 75 ２１ / I ２ and a first medium density polyethylene (MDPE) having a density of 0.933 g / cc to 0.935 g / cc and an I of 25 to 40. ２１ / I ２ a second ethylene-based polymer having a ratio of forming a blend component comprising 35 wt% to 45 wt% of the first MDPE, 60 wt% to 55 wt% of the second ethylene-based polymer, and 1 wt% to 7 wt% carbon black, wherein the blend component has a density of 0.935 g / cc to less than 0.945 g / cc and an I of 35 to 55. ２１ / I ２ forming a extruding the blend components onto the conductor at a velocity greater than 1.02 m / sec; forming a conductor jacket having a surface smoothness of 40 μin to 60 μin (1.02 μm to 1.52 μm).

8. 8. The process of claim 7, comprising forming a conductor jacket having a tensile strength of 27 MPa to 30 MPa and a tensile elongation of 830% to 970%.

9. Density of 0.933 g / cc to 0.937 g / cc and I of 63 to 67 ２１ / I ２ and a first medium density polyethylene (MDPE) having a density of 0.933 g / cc to 0.935 g / cc and an I of 25 to 30. ２１ / I ２ a second MDPE having a ratio of forming a blend component comprising 35% to 45% by weight of the first MDPE, 60% to 55% by weight of the second MDPE, and 1% to 7% by weight of carbon black, wherein the blend component has a density of 0.935 g / cc to less than 0.945 g / cc and an I of 40 to 45; ２１ / I ２ forming a extruding the blend components onto the conductor at a velocity greater than 1.02 m / sec; forming the conductor jacket having a surface smoothness of 50 μin to 60 μin (1.27 μm to 1.52 μm).

10. 10. The process of claim 9, comprising forming a conductor jacket having a tensile strength of 27 MPa to 30 MPa and a tensile elongation of 860% to 970%.

11. A process for manufacturing a conductor jacket, comprising: 55-85 I ２１ / I ２ a first ethylene-based polymer having an I ratio of 20 to 50; ２１ / I ２ a second ethylene-based polymer having a ratio of forming a blend component comprising 20% ​​to 70% by weight of the first ethylene-based polymer, 80% to 20% by weight of the second ethylene-based polymer, and optional carbon black; The blend components have a density of 0.925 g / cc to 0.955 g / cc and an I ２１ / I ２ forming a ratio of extruding the blend components onto a conductor at a velocity greater than 1.02 m / sec; forming a conductor jacket having a surface smoothness of 20 μin to 80 μin (0.51 μm to 2.03 μm).

12. Density of 0.915 g / cc to 0.925 g / cc and I of 73 to 77 ２１ / I ２ a first linear low density polyethylene (LLDPE) having a ratio of 0.915 g / cc to 0.925 g / cc and an I of 20 to 35; ２１ / I ２ a second LLDPE having a ratio of forming a blend component comprising 50% to 70% by weight of the first LLDPE, 49% to 20% by weight of the second LLDPE, and 1% to 10% by weight of carbon black, wherein the blend component has a density of 0.925 g / cc to less than 0.935 g / cc and an I of 33 to 60; ２１ / I ２ forming a ratio of extruding the blend components onto the conductor at a velocity greater than 1.02 m / sec; forming the conductor jacket having a surface smoothness of 30 μin to 80 μin (0.76 μm to 2.03 μm).

13. Density of 0.933 g / cc to less than 0.937 g / cc and I of 55 to 75 ２１ / I ２ and a first medium density polyethylene (MDPE) having a density of 0.935 g / cc to 0.940 g / cc and an I of 25 to 40. ２１ / I ２ a second medium density polyethylene (MDPE) having a ratio of forming a blend component comprising 50% to 70% by weight of the first MDPE, 49% to 20% by weight of the second MDPE, and 1% to 10% by weight of carbon black, wherein the blend component has a density of 0.935 g / cc to 0.950 g / cc and an I of 35 to 50; ２１ / I ２ forming a extruding the blend components onto the conductor at a velocity greater than 1.02 m / sec; forming the conductor jacket having a surface smoothness of 20 μin to 60 μin (0.51 μm to 1.52 μm).

14. Density of 0.933 g / cc to less than 0.937 g / cc and I of 55 to 75 ２１ / I ２ and a first medium density polyethylene (MDPE) having a density of 0.915 g / cc to 0.925 g / cc and an I of 20 to 40. ２１ / I ２ a second linear low density polyethylene (LLDPE) having a ratio of forming a blend component comprising 50% to 70% by weight of said first MDPE, 49% to 20% by weight of said second LLDPE, and 1% to 10% by weight of carbon black, said blend component having a density of 0.935 g / cc to 0.950 g / cc and an I of 40 to 65; ２１ / I ２ forming a extruding the blend components onto the conductor at a velocity greater than 1.02 m / sec; forming the conductor jacket having a surface smoothness of 20 μin to 60 μin (0.51 μm to 1.52 μm).

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