Foamed Silane-Crosslinked Cable Jacket for Flexible Stripping
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Solution Overview
Problem
Existing cable jackets lack flexibility and ease of stripping, which complicates installation and increases the risk of damage during installation, especially in power stations where high flexibility is required.
Innovation Solution
A cable jacket composition comprising an expandable and crosslinkable blend of polyolefin material with silane moieties and a foaming system, allowing for increased flexibility and ease of stripping without the need for reactive silane grafting during extrusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a jacket material with higher melting point is selected to tolerate higher temperatures, then the dimension (thickness) of copper threads in the outer screen can be decreased, but the jacket material becomes stiffer which significantly contributes to a stiffer power cable
Solution Approach 1:
The patent uses a composite material system consisting of polyethylene base polymer combined with silane grafts and peroxide crosslinking agents. This composite approach allows the jacket to achieve high melting point (thermal stability) through crosslinked network structure while maintaining flexibility through the polyethylene matrix, thus resolving the contradiction between temperature resistance and cable flexibility
Solution Approach 2:
The patent changes the chemical and physical parameters of the jacket material by introducing silane moieties and peroxide crosslinking. This transforms the material from simple polyethylene to a crosslinked silane-modified polyethylene, altering its thermal and mechanical properties to simultaneously achieve high melting point and maintained flexibility
2Temperature
If reactive silane grafting is performed during extrusion to achieve crosslinking, then thermal stability is improved, but the process complexity and manufacturing difficulty increase
Solution Approach 1:
The patent applies preliminary action by pre-grafting silane groups onto the polyethylene chains before extrusion. This preliminary modification allows the crosslinking reaction to occur more easily during or after extrusion without requiring complex in-line reactive extrusion equipment, thus improving thermal stability while keeping the manufacturing process relatively simple
Solution Approach 2:
The patent uses peroxide as an intermediary substance that facilitates the crosslinking reaction between silane groups. The peroxide acts as a catalyst/mediator that enables crosslinking to occur under mild conditions during or after extrusion, avoiding the need for complex high-energy processing while achieving the desired thermal stability
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 cable jacket composition achieves improved flexibility and thermal stability, enabling thinner metallic screens and easier installation, while maintaining high resistance to breakage during installation and reduced material costs.
Implementation Method 1
via hydrolysable silane groups present in the polymer using a condensation catalyst in the presence of water
Implementation Method 2
via hydrolysable silane groups present in the polymer using a condensation catalyst in the presence of water
Implementation Method 3
A cable jacket composition comprising an expandable and crosslinkable blend of polyolefin material with silane moieties and a foaming system
Data Source
Figure 1
AI summary
The present invention relates to a cable jacket composition comprising an expandable and crosslinkable jacket blend of: a polymer composition comprising a polyolefin material, which polyolefin material bears silane moieties, and a foaming system, wherein the provided jacket blend will comprise at least 0.1 % by weight of a foaming agent, with respect to the total weight of the polyolefin material; cable jacket; cable, e.g. a power cable or a communication cable; and uses thereof.