Crosslinked Cable Process Using Peroxide to Eliminate Voids
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Solution Overview
Problem
The existing process for producing crosslinked cables using free radical generating agents, such as peroxides, results in the formation of volatile decomposition products like methane, which lead to voids in the cable layers, reducing electrical strength and requiring a costly and time-consuming degassing step to remove, while also posing safety risks due to flammability and explosiveness.
Innovation Solution
A process involving the use of a specific free radical generating agent that minimizes the formation of volatile decomposition products, allowing for crosslinking and cooling under pressurized conditions without the need for a degassing step, thereby reducing voids and improving cable quality and processing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional peroxides (e.g., dicumylperoxide) are used as free radical generating agents for crosslinking, then crosslinking reaction is initiated and cable layers are formed, but volatile decomposition products (e.g., methane) are generated causing voids, safety risks, and requiring costly degassing steps
Solution Approach 1:
The patent changes the chemical parameters of the free radical generating agent by selecting peroxides with specific molecular structures (formula I) that have different decomposition characteristics. This parameter change eliminates the formation of volatile decomposition products while maintaining the crosslinking function, directly resolving the contradiction between cable quality and harmful factors
Solution Approach 2:
The patent converts the harmful volatile decomposition products into non-volatile or minimal decomposition products through careful selection of peroxide structure. The decomposition still provides the necessary free radicals for crosslinking but without the harmful gaseous byproducts, turning a harmful process into a beneficial one
2Manufacturing precision
If a degassing step is implemented to remove volatile decomposition products, then voids are reduced and cable quality is improved, but production time and energy consumption increase significantly
Solution Approach 1:
The patent performs preliminary action by selecting peroxides that do not generate volatile decomposition products in the first place. This preventive approach eliminates the need for subsequent degassing operations, saving both time and energy while achieving the same void reduction goal
Solution Approach 2:
The patent extracts the problematic volatile decomposition products from the decomposition pathway by selecting peroxides with appropriate molecular structures. This extraction of the harmful element eliminates the need for degassing while maintaining crosslinking effectiveness
3Strength
If peroxides are used for crosslinking, then mechanical strength and deformation resistance are improved, but flammable and explosive gases are generated creating safety risks
Solution Approach 1:
The patent changes the chemical composition parameters of the peroxide to eliminate flammable and explosive decomposition products. By selecting peroxides with specific molecular structures (formula I), the decomposition produces non-hazardous products while maintaining the free radical generation capability needed for crosslinking and mechanical strength improvement
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 process results in a crosslinked cable with reduced voids and improved electrical strength, safer handling, and reduced energy and time consumption in the manufacturing process, as well as enhanced processing efficiency by eliminating the need for a degassing step.
Implementation Method 1
free radical generating agents act by generating radicals, typically by decomposing to radicals, under conditions which enable the radical formation
Implementation Method 2
crosslinking in a polymer, i.a. primarily formation of interpolymer crosslinks (bridges) by radical reaction
Implementation Method 3
cooling the obtained crosslinked cable under pressurized conditions to a cooled temperature
Data Source
AI summary
The application relates to a process for preparing a crosslinked cable, including:—applying one or more layers including a polymer composition on a conductor, wherein at least one layer includes one or more free radical generating agents,—crosslinking by radical reaction said at least one layer comprising said free radical generating agent(s),—cooling the obtained crosslinked cable in pressurized conditions.