Crosslinked Cable Process Minimizing Volatile Decomposition
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Solution Overview
Problem
The existing process for crosslinking cables using free radical generating agents, such as peroxides, results in the formation of volatile decomposition products like methane, which are hazardous and require a time-consuming and costly degassing step to remove, leading to potential defects and reduced electrical strength in cables.
Innovation Solution
A process involving the use of a specific compound as a free radical generating agent that minimizes the formation of volatile decomposition products, allowing for crosslinking under pressurized conditions and either reducing or removing these products at ambient or elevated temperatures, thereby eliminating the need for a degassing step and improving cable quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional peroxides like dicumylperoxide are used as free radical generating agents for crosslinking, then crosslinking efficiency is improved, but volatile decomposition products like methane are formed which require time-consuming and costly degassing steps
Solution Approach 1:
The patent changes the chemical structure parameters of the peroxide molecule by replacing at least one methyl group with a hydrogen atom, creating novel peroxide compounds with modified decomposition behavior that produces fewer volatile by-products while maintaining crosslinking efficiency
Solution Approach 2:
The patent converts the harmful effect of volatile decomposition products into a benefit by designing peroxides whose decomposition produces minimal volatiles, thereby eliminating the need for lengthy degassing steps and turning a previously harmful requirement into a process advantage
2Power
If conventional peroxides are used for crosslinking, then crosslinking reaction is effective, but flammable and explosive volatile decomposition products are generated creating safety risks
Solution Approach 1:
The patent modifies the molecular parameters of the peroxide by substituting methyl groups with hydrogen atoms, changing the decomposition pathway to produce non-flammable or less flammable by-products, thereby eliminating safety hazards while preserving crosslinking effectiveness
Solution Approach 2:
The patent transforms the safety hazard of flammable decomposition products into a safety advantage by designing peroxides that decompose into benign substances, converting a harmful process into a safe one without compromising the crosslinking reaction
3Quantity of substance
If degassing is performed at elevated temperatures to remove volatile decomposition products, then volatile removal is improved, but thermal expansion and softening of the insulation layer occur causing cable deformation
Solution Approach 1:
The patent changes the fundamental parameter of volatile generation by using modified peroxide structures that produce minimal volatiles, thereby eliminating the need for high-temperature degassing and avoiding the associated deformation problems
Solution Approach 2:
The patent converts the harmful effect of requiring high-temperature degassing into a benefit by designing a system where minimal volatiles are produced, allowing degassing to be performed at lower temperatures that prevent insulation layer deformation
4Quantity of substance
If lengthy degassing steps are performed to remove volatile decomposition products, then volatile content is reduced, but production time and energy consumption increase
Solution Approach 1:
The patent fundamentally changes the volatile generation parameter by using peroxides with modified chemical structures that produce minimal volatiles, thereby drastically reducing or eliminating the need for lengthy degassing operations and improving production efficiency
Solution Approach 2:
The patent transforms the harmful time and energy consumption of lengthy degassing into a benefit by designing peroxides that inherently produce minimal volatiles, converting a inefficient process step into a streamlined operation
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
This approach significantly reduces the time and energy required for cable production, enhances the quality of crosslinked cables by minimizing voids and improving processability, and eliminates the risks associated with volatile decomposition products, resulting in a safer and more efficient manufacturing process.
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
the cable must be cooled with great care to prevent the gaseous volatile decomposition products like methane forming voids within the polymer layer
Data Source
AI summary
The invention relates to a process for preparing a crosslinked cable, comprising: -applying one or more layers comprising a polymer composition on a conductor, wherein at least one layer comprises 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, and - reducing or removing the content of volatile decomposition products(s), which are originating from optionally in elevated temperature, from the crosslinked cable obtained from cooling and recovery step.