Ethylene Copolymer Insulation with TAP Crosslinking
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Solution Overview
Problem
Existing ethylene/alpha-olefin copolymer compositions used in insulated electrical/optical conductors lack sufficient flexibility and heat/oxidative stability for medium-to-ultra-high voltage applications, leading to reduced performance over time due to embrittlement and oxidation.
Innovation Solution
A peroxide-curable ethylene copolymer composition comprising a crosslinkable ethylene/alpha-olefin copolymer, triallyl phosphate, and an organic peroxide, which is cured to form a crosslinked product with enhanced flexibility, heat stability, and reduced dissipation factor, suitable for use as a single or multilayer insulation in insulated electrical/optical conductors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional ethylene/alpha-olefin copolymer compositions are used, then the material provides basic insulation properties, but the flexibility and heat/oxidative stability are insufficient for medium-to-ultra-high voltage applications
Solution Approach 1:
The patent creates a composite crosslinked system by combining ethylene/alpha-olefin copolymer with triallyl phosphate crosslinking agent and peroxide initiator. This composite approach produces a network structure that simultaneously delivers enhanced heat/oxidative stability and maintains flexibility, resolving the contradiction between these two properties in medium-to-ultra-high voltage insulation applications
Solution Approach 2:
The patent modifies the chemical structure and crosslinking density parameters of the polyolefin insulation material through controlled crosslinking reactions. By adjusting crosslinking agent content, peroxide concentration, and curing conditions, the material achieves optimal balance between flexibility and heat/oxidative stability for high-voltage applications
2Temperature
If polyolefin coverings are exposed to heat for prolonged periods, then the material provides thermal resistance, but the flexibility is reduced and oxidation and embrittlement occur
Solution Approach 1:
The patent converts the harmful effect of heat exposure that causes oxidation and embrittlement into a beneficial crosslinking process. The peroxide initiator decomposes under heat to generate radicals that crosslink the polymer chains, transforming thermal energy that would normally degrade the material into a mechanism that enhances its thermal stability and service life
Solution Approach 2:
The patent applies crosslinking agents and initiators in advance during material fabrication, creating a pre-formed crosslinked network structure before the insulation is installed. This preliminary crosslinking action ensures the material is pre-conditioned to resist heat-induced oxidation and embrittlement throughout its service life
3Reliability
If crosslinking is increased to improve heat stability, then the oxidative induction time increases, but the dissipation factor may worsen
Solution Approach 1:
The patent optimizes the chemical composition parameters including the type and concentration of crosslinking agent, peroxide initiator, and catalyst system to achieve the desired balance. By carefully controlling these parameters, the material attains high oxidative induction time while maintaining acceptable dissipation factor for electrical insulation performance
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 resulting crosslinked product exhibits improved tensile elongation retention, oxidative induction time, and reduced dissipation factor, ensuring enhanced performance and durability in high-voltage applications.
Implementation Method 1
a crosslinkable ethylene/alpha-olefin copolymer, triallyl phosphate, and an organic peroxide, which is cured to form a crosslinked product
Implementation Method 2
copolymerizing ethylene and an olefin-functional comonomer
Data Source
AI summary
A peroxide-curable ethylene copolymer composition comprising (A) a crosslinkable ethylene/alpha-olefin copolymer, (B) an effective amount of triallyl phosphate (TAP), (C) an organic peroxide; and, optionally, (D) a supplemental polymer; wherein the (A) crosslinkable ethylene/alpha-olefin copolymer is made by copolymerizing ethylene and an olefin-functional comonomer in the presence of a molecular catalyst useful therefor. Also provided are a cured product made from the composition, methods of making and using same, and articles containing same.