Silane-Modified Cable Polymer for Polyurethane Adhesion

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Solution Overview

Problem

Existing cable manufacturing processes for low voltage power cables are complex due to the need for crosslinking insulation and jacketing in vulcanization tubes, and there is a lack of adequate adhesion between polyethylene and polyurethane resins, which can lead to disrupted joints under mechanical stress.

Innovation Solution

A polyethylene composition comprising ethylene copolymers with monomer units of polar groups and hydrolysable silane groups, along with a silanol condensation catalyst, is used to improve adhesion to polyurethane resins, allowing for ambient crosslinking without additional vulcanization tubes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If peroxide crosslinked EPR is used for insulation and jacketing, then crosslinking strength is improved, but manufacturing process complexity increases due to required vulcanization tubes

Engineering Contradiction:

Improvecrosslinking strengthVSAvoidmanufacturing process complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent changes the crosslinking mechanism from peroxide-based (requiring vulcanization) to moisture-cure silane crosslinking. The polyethylene composition incorporates hydrolysable silane groups that crosslink upon exposure to moisture, eliminating the need for vulcanization tubes and high-temperature processing while maintaining crosslinking strength.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the mechanical/thermal vulcanization system with a chemical moisture-cure system. Instead of using peroxide crosslinking that requires vulcanization equipment, the invention uses silane groups that automatically crosslink when exposed to ambient moisture, substituting a complex mechanical process with a simpler chemical reaction.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Strength

If polyethylene composition is used as insulation layer, then good adhesion to polyurethane resin is required, but conventional polyethylene shows poor adhesion

Engineering Contradiction:

Improveadhesion strengthVSAvoidjoint durability under mechanical stress

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent creates a composite polyethylene material that combines conventional polyethylene with hydrolysable silane groups and polar groups. This composite structure provides both the mechanical properties of polyethylene and the adhesion properties needed for strong bonding to polyurethane resin, preventing joint disruption under mechanical stress.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent introduces polar groups and silane groups at specific locations within the polyethylene structure to enhance adhesion. These functional groups are incorporated into the polyethylene composition to create localized adhesion zones that improve bonding to polyurethane resin without compromising the overall polyethylene properties.

Inventive Principle:

Principle #3Local quality

3Adaptability or versatility

If flexible cable materials are used to achieve flexural modulus below 30 MPa, then cable flexibility is improved, but crosslinking process becomes more challenging

Engineering Contradiction:

Improvecable flexibilityVSAvoidcrosslinking process ease

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent enables the flexible cable material to self-crosslink through moisture exposure. The hydrolysable silane groups in the polyethylene composition automatically react with ambient moisture to form crosslinks, eliminating the need for external vulcanization equipment and complex crosslinking processes, thereby maintaining flexibility while achieving crosslinking.

Inventive Principle:

Principle #25Self-service

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution provides improved adhesion and mechanical properties, enabling durable cable joints with enhanced flexibility and reduced scorch risk, while meeting mechanical and flexibility standards for low voltage cables.

Implementation Method 1

monomer units with hydrolysable silane groups

Methodology Applied

Scientific EffectHydrolysis: Hydrolysis

Implementation Method 2

silanol condensation catalyst

Methodology Applied

Scientific EffectSilane condensation: Chemical Bonding

Implementation Method 3

monomer units with polar groups present in an amount of more than 5 mol. %

Methodology Applied

Scientific EffectPolar interaction: Van der Waals Force

Data Source

PatentUS12404392B2Moisture cureable polymer for flexible cables

Publication Date: 2025.09.02 BOREALIS AG

AI summary

The invention relates to the use of a polyethylene composition comprising one or more ethylene copolymer(s) wherein the ethylene copolymer is a terpolymer containing monomer units with polar groups and monomer units with hydrolysable silane groups, wherein the monomer units with polar groups are present in an amount of more than 5 mol. % based on the total polyethylene composition, and a silanol condensation catalyst in an amount of 0.0001 to 5 wt. %, based on the total polyethylene composition for improving the adhesion between a layer of a cable comprising the polyethylene composition and a polyurethane resin.