Amorphous Silica Filler for Elastomer Insulation

Solution Overview

Problem

Elastomer-based polymeric compounds used as electrical insulation materials face challenges with clay fillers, which improve melt extrudate quality but increase electrical loss properties, such as high tan delta, exceeding acceptable levels.

Innovation Solution

A polymeric composition comprising an ethylene/α-olefin-based elastomer with amorphous silica as the primary filler, ranging from 5 to 40 weight percent, including treated fumed silica or silica aerogels, to reduce electrical loss while maintaining processing performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If clay fillers are used in elastomer-based polymeric compounds, then melt extrudate quality and cable concentricity are improved, but electrical loss properties increase (high tan delta)

Engineering Contradiction:

Improvemelt extrudate qualityVSAvoidelectrical loss (tan delta)

Core Design Contradiction:

Manufacturing precisionVSLoss of energy

Solution Approach 1:

The patent changes the filler material parameter from clay to amorphous silica, fundamentally altering the composition's electrical properties while maintaining processing benefits. This substitution reduces tan delta from unacceptable levels to below 0.006, resolving the electrical loss issue while preserving melt extrudate quality and cable concentricity

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite material system combining ethylene/alpha-olefin elastomer with amorphous silica filler, where the specific combination of polymer matrix and silica particles achieves both good processing performance and low electrical loss. The composite structure allows the filler to provide mechanical benefits without the electrical drawbacks of clay

Inventive Principle:

Principle #40Composite materials

2Stability of the object's composition

If clay fillers are used to maintain cable concentricity, then sufficient melt strength is provided, but electrical loss properties increase

Engineering Contradiction:

Improvecable concentricityVSAvoidelectrical loss (tan delta)

Core Design Contradiction:

Stability of the object's compositionVSLoss of energy

Solution Approach 1:

The patent changes the filler material parameter from clay to amorphous silica, fundamentally altering the composition's electrical properties while maintaining processing benefits. This substitution reduces tan delta from unacceptable levels to below 0.006, resolving the electrical loss issue while preserving melt extrudate quality and cable concentricity

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses amorphous silica as a filler that provides the necessary structural support and melt strength temporarily during processing, after which the cured elastomer matrix maintains cable concentricity without the harmful electrical effects of clay fillers

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Data Source

PatentEP2935452B1Elastomer-based polymeric compositions having amorphous silica fillers

Publication Date: 2018.10.10 DOW GLOBAL TECHNOLOGIES LLC

AI summary

Polymeric compositions suitable for use as insulation materials in electrical applications. Such polymeric compositions comprise an ethylene/α-olefin-based elastomer and a filler, where the filler consists essentially of an amorphous silica. Such polymeric compositions can optionally further comprise an ethylene-based thermoplastic polymer. Also disclosed are coated conductors comprising such polymeric compositions as insulation materials.