Fluorinated Peroxide Crosslinking Agents for Cable Manufacturing
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Solution Overview
Problem
The use of free radical generating agents like peroxides in polymer compositions for cable manufacturing results in the formation of volatile decomposition products, such as methane, which can lead to voids and reduce the electrical strength of cables, necessitating a costly and energy-intensive degassing step to minimize these products.
Innovation Solution
A compound with a specific formula that generates reduced or no detectable amounts of undesired decomposition products, particularly methane, when used as a free radical generating agent in polymer crosslinking processes, thereby minimizing void formation and improving cable quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional peroxides like dicumylperoxide are used as free radical generating agents for polymer crosslinking, then crosslinking efficiency is improved, but volatile decomposition products like methane are generated causing voids and reducing cable quality
Solution Approach 1:
The patent changes the chemical structure parameters of the peroxide molecule by replacing hydrogen atoms with fluorine atoms and introducing trifluoromethyl groups. This structural modification fundamentally alters the decomposition pathway to eliminate volatile hydrocarbon products while maintaining radical generation capability for crosslinking.
Solution Approach 2:
The patent converts the harmful volatile decomposition products into beneficial non-volatile or minimal volatile products. The fluorinated peroxide decomposes to produce carbon dioxide and water vapor instead of flammable hydrocarbons, transforming a hazardous process into a safer one while maintaining crosslinking effectiveness.
2Manufacturing precision
If degassing step is implemented to remove volatile decomposition products, then cable quality is improved, but processing time and energy consumption increase
Solution Approach 1:
The patent performs preliminary action by designing a peroxide compound that inherently produces minimal volatile decomposition products from the start. This prevents the formation of void-causing gases before the crosslinking process begins, eliminating the need for subsequent degassing operations and reducing overall processing time.
Solution Approach 2:
The patent extracts the problematic volatile decomposition products from the decomposition pathway of the peroxide by using fluorinated structures. The decomposition is directed toward non-volatile or minimal volatile products, effectively removing the source of quality defects without requiring additional extraction or removal steps.
3Power
If conventional peroxides are used, then crosslinking reaction is initiated effectively, but safety risks increase due to flammable and explosive volatile products
Solution Approach 1:
The patent converts the harmful flammable and explosive hydrocarbon decomposition products into safe carbon dioxide and water vapor. The fluorinated peroxide maintains effective radical generation for crosslinking while producing non-flammable decomposition products, thereby eliminating safety hazards associated with conventional peroxides.
Solution Approach 2:
The fluorinated peroxide creates an inherently safer, non-flammable environment during decomposition. By replacing hydrogen with fluorine, the decomposition products become non-combustible, effectively creating an inert atmosphere that eliminates fire and explosion risks during the crosslinking 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 compound significantly reduces volatile by-products, enhancing cable quality and safety by eliminating the need for extensive degassing, thus improving processing efficiency and reducing environmental risks.
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
initiate (a) crosslinking in a polymer, i.a. primarily formation of interpolymer crosslinks (bridges) by radical reaction
Data Source
AI summary
Compounds for use as radical generating agents for modifying polymer compositions, wherein the modified polymer compositions and the process for preparing the polymer compositions are utilized with wires or cables thereby forming one or more layers of a wire of the cable.