LDPE-Polypropylene Cable Composition Without Peroxide Crosslinking

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Solution Overview

Problem

Existing polyolefin compositions used in cable applications require peroxides for crosslinking, leading to undesirable by-products, increased production costs, and limited melt temperature, which affects electrical properties and production efficiency.

Innovation Solution

A polymer composition comprising LDPE, polypropylene, and polyolefins with epoxy and carboxylic acid groups, which react in situ to form a compatibilizer network without peroxides, enhancing thermomechanical properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If peroxides are used for crosslinking, then thermomechanical properties are improved, but harmful by-products are generated and production costs increase

Engineering Contradiction:

Improvethermomechanical propertiesVSAvoidperoxide decomposition by-products

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The patent converts the harmful peroxide crosslinking process into a beneficial alternative by using epoxy-functionalized polyolefin and carboxylic acid-functionalized polyolefin that react to form crosslinks without peroxides. The epoxy groups react with carboxylic acid groups to create crosslinked structures, eliminating the generation of harmful peroxide decomposition by-products while maintaining improved thermomechanical properties.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent changes the chemical parameters of the crosslinking process by replacing peroxide-based crosslinking with epoxy-carboxylic acid crosslinking. This parameter change eliminates the need for peroxides and their associated harmful by-products, while still achieving the desired crosslinked network structure for improved thermomechanical properties.

Inventive Principle:

Principle #35Parameter changes

2Strength

If peroxides are used for crosslinking, then thermomechanical properties are improved, but production costs and process complexity increase

Engineering Contradiction:

Improvethermomechanical propertiesVSAvoidproduction process complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent merges the crosslinking function into the polymer composition itself by incorporating epoxy-functionalized polyolefin and carboxylic acid-functionalized polyolefin directly into the extrusion process. This eliminates the need for separate peroxide addition steps and subsequent crosslinking steps, reducing production process complexity while maintaining improved thermomechanical properties.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent enables the polymer composition to self-crosslink through the reaction between epoxy groups and carboxylic acid groups during extrusion or subsequent heating. This self-service crosslinking mechanism eliminates the need for external peroxide agents and complex multi-step crosslinking processes, simplifying production while achieving improved thermomechanical properties.

Inventive Principle:

Principle #25Self-service

3Strength

If peroxides are used for crosslinking, then crosslinking density is increased, but melt temperature is limited and production speed decreases

Engineering Contradiction:

Improvecrosslinking densityVSAvoidproduction speed

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The patent changes the temperature parameter range by using epoxy-carboxylic acid crosslinking instead of peroxide crosslinking. The epoxy-carboxylic acid reaction can proceed at higher temperatures without causing premature crosslinking or gel formation, allowing the extruder to operate at optimal temperatures for high production speed while still achieving high crosslinking density in the final product.

Inventive Principle:

Principle #35Parameter changes

4Strength

If peroxides are used for crosslinking, then thermomechanical properties are improved, but degassing steps are required

Engineering Contradiction:

Improvethermomechanical propertiesVSAvoidproduction time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The patent eliminates the harmful peroxide decomposition by-products that require degassing by using epoxy-carboxylic acid crosslinking instead. This conversion removes the need for time-consuming degassing steps from the production process, reducing production time while maintaining improved thermomechanical properties.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 composition provides improved thermomechanical properties and eliminates the need for peroxides, reducing production costs and enhancing electrical properties without the need for degassing steps.

Implementation Method 1

a polyolefin (A) comprising epoxy groups; and a polyolefin (B) comprising carboxylic acid groups, or precursors thereof

Methodology Applied

Scientific EffectChemical Bonding: Chemical Bonding

Data Source

PatentUS12584003B2Compositions comprising LDPE, polypropylene and functionalised polyolefins

Publication Date: 2026.03.24 BOREALIS AG

AI summary

The invention provides a polymer composition comprising (i) an LDPE; (ii) a polypropylene; (iii) polyolefin (A) comprising epoxy groups; and (iii) polyolefin (B) comprising carboxylic acid groups and/or precursor thereof.