Epoxy Cross-Linked Cable Layer Without Peroxide By-Products
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Electrical cables face issues with the decomposition of peroxide-cross-linked layers, leading to the formation of harmful by-products like methane and water, which can cause breakdown and pose explosive risks, and existing solutions to mitigate these issues are time-consuming and costly.
Innovation Solution
A cross-linked layer is developed using a polymer composition comprising epoxy functions and a cross-linking agent selected from non-aromatic cyclic amines and imidazoles, which eliminates the need for organic peroxides, enhancing cross-linking speed and density while being economical and easy to manufacture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If peroxide cross-linking is used to create cross-linked layers, then cross-linking density is achieved, but harmful by-products (methane, water) are formed that cause breakdown and explosive risks
Solution Approach 1:
The patent changes the chemical parameters of the cross-linking system by replacing peroxide with silane and catalyst. This substitution fundamentally alters the cross-linking chemistry to eliminate harmful by-products while maintaining cross-linking density. The silane cross-linking system produces water as the only by-product, which is then removed through controlled hydrolysis and condensation reactions.
Solution Approach 2:
The patent converts the potentially harmful water by-product into a beneficial element by using it as the cross-linking mechanism itself. The water produced during silane hydrolysis and condensation actually drives the cross-linking reaction, forming the desired cross-linked network. This transforms what would be a harmful by-product into the essential medium for achieving cross-linking.
2Object-generated harmful factors
If thermal treatment is applied to accelerate methane diffusion, then methane removal is improved, but manufacturing time and cost increase significantly
Solution Approach 1:
The patent extracts the harmful methane by-product from the system by replacing the peroxide cross-linking mechanism with silane cross-linking. This eliminates the source of methane generation entirely, removing the need for subsequent thermal treatment to accelerate methane diffusion. The only by-product generated is water, which is managed through the cross-linking process itself rather than requiring separate removal steps.
3Speed
If peroxide cross-linking is used, then cross-linking speed is achieved, but harmful decomposition products are formed
Solution Approach 1:
The patent changes the chemical parameters of the cross-linking system by substituting peroxide with silane and catalyst. This substitution maintains cross-linking speed through the catalyzed hydrolysis and condensation reactions of silane groups, while fundamentally altering the by-products from harmful peroxide decomposition products to benign water molecules that are integrated into the cross-linking process.
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 significantly reduces the presence of cross-linking by-products, improves cross-linking time and density, and eliminates the need for restrictive degassing processes, making the manufacturing process more efficient and cost-effective.
Implementation Method 1
the cross-linking agent is selected from: a non-aromatic cyclic amine, an imidazole of formula (I)... capable of reacting with the epoxy function of said polymer
Data Source
AI summary
An electrical device includes at least one cross-linked layer obtained from a polymer composition that has:at least one polymer comprising one or more epoxy function(s), andat least one cross-linking agent. The cross-linking agent is selected from:a non-aromatic cyclic amine,an imidazole of formula (I) where R1 and R2 independently represent a hydrogen atom or a hydrocarbon group, R3 and R4 independently represent a hydrogen atom or a hydrocarbon group, or R3 and R4 form, together with the carbon atoms of the imidazole ring to which they are attached, a ring, with the imidazole being associated with a cross-linking co-agent having at least one reactive function capable of reacting with the epoxy function of said polymer, and, a mixture thereof.