Copper Passivator Polymer Layer for Cable Discoloration

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Solution Overview

Problem

Copper conductors in electrical cables are prone to discolouration due to reactions with atmospheric oxygen and moisture, leading to aesthetic and performance issues, and existing protective methods like applying benzotriazole compounds directly on the surface can be damaged during cable extrusion or installation.

Innovation Solution

A polymer layer adjacent to the copper conductor, comprising a polymer of ethylene with hydrolysable silane groups and a benzotriazole compound, forms a protective layer that migrates to the copper surface, providing self-healing protection against discolouration and acting as a reservoir for the benzotriazole compound.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If benzotriazole compound is applied directly onto copper surface, then copper discolouration is protected, but the protective layer can be scratched and destroyed during cable extrusion or installation

Engineering Contradiction:

Improveprotection against copper discolourationVSAvoidmechanical durability of protective layer

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent uses the polymer insulation layer as an intermediary carrier to deliver the benzotriazole compound to the copper surface. Instead of applying benzotriazole directly to copper (which creates a fragile protective layer), the compound is first incorporated into the polymer matrix, which then migrates benzotriazole to the copper surface over time. This intermediary approach protects the copper while avoiding mechanical damage to the protective layer during cable extrusion and installation.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The benzotriazole compound is pre-incorporated into the polymer insulation layer during cable manufacturing, before the cable is installed. This preliminary action ensures that the protective compound is already in position and will migrate to the copper surface over time, providing continuous protection without requiring direct application to the copper surface that would be vulnerable to mechanical damage.

Inventive Principle:

Principle #10Preliminary action

2Object-affected harmful factors

If copper conductor is exposed to atmospheric oxygen and moisture, then copper discolouration occurs, but protecting the copper surface with direct application of passivator can be damaged during installation

Engineering Contradiction:

Improvecopper discolouration from oxygen and moistureVSAvoidlong-term protection stability

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The polymer insulation layer serves as a self-service reservoir that continuously supplies benzotriazole compound to the copper surface. The polymer matrix slowly releases the passivator compound over time, allowing the system to self-regulate and maintain protective levels without external intervention. This ensures long-term protection stability while the polymer itself remains intact and undamaged during installation.

Inventive Principle:

Principle #25Self-service

3Reliability

If polymer layer contains benzotriazole compound, then copper protection is provided, but the compound needs to be protected from premature loss

Engineering Contradiction:

Improvecopper corrosion protectionVSAvoidbenzotriazole compound loss

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The polymer insulation layer acts as a flexible shell or matrix that encapsulates and protects the benzotriazole compound. This polymer shell prevents premature loss of the compound while allowing controlled migration to the copper surface. The flexible polymer matrix maintains the integrity of the benzotriazole compound until it is needed at the copper interface, preventing both premature loss and ensuring reliable protection.

Inventive Principle:

Principle #30Flexible shells and thin films

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 polymer layer effectively prevents copper discolouration, maintains crosslinking properties, and ensures long-term protection against corrosion and moisture exposure, even when exposed to demanding environments.

Implementation Method 1

a polymer layer adjacent to the copper conductor, wherein the polymer layer comprises a polymer composition comprising a polymer of ethylene, which comprises a comonomer with silane groups containing units that are hydrolysable, and a benzotriazole compound

Methodology Applied

Scientific EffectMigration: Diffusion

Implementation Method 2

a comonomer with silane groups containing units that are hydrolysable

Methodology Applied

Scientific EffectHydrolysis: Hydrolysis

Implementation Method 3

If benzotriazole compound is applied onto a copper surface it will protect the surface from discolouration. It will form a protective benzotriazole-copper polymeric network.

Methodology Applied

Scientific EffectAdsorption: Adsorption

Data Source

PatentEP3035345B1Layered structure with copper passivator

Publication Date: 2020.05.06 BOREALIS AG

AI summary

The present invention relates to a layered structure comprising a copper conductor and a polymer layer adjacent to the copper conductor, more specific to a wire or cable insulation layer that can preserve the copper conductor from discolouration. The polymer layer adjacent to the copper conductor comprises the polymer composition comprising a benzotriazole compound. This prevents discoloration of the copper conductor.