Multimodal Ethylene Copolymer Cable Layer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current polyethylene (PE) polymers used in cable applications face challenges in balancing high flexibility with high heat distortion temperature, and their processability is often compromised, making them unsuitable for demanding wire and cable (W&C) applications where stringent regulations must be met.
Innovation Solution
A cable comprising a conductor surrounded by layers, with at least one layer made of a multimodal copolymer of ethylene, comprising a combination of higher and lower density copolymers produced using a single site catalyst, which offers improved mechanical properties and processing feasibility, including a jacketing layer with enhanced flexibility and heat distortion temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a polyethylene polymer is designed to have high flexibility, then the flexibility is improved, but the heat distortion temperature decreases
Solution Approach 1:
The patent applies composite materials by combining two distinct polyethylene fractions with different densities and molecular weights into a single multimodal polymer composition. The first fraction (higher density, lower molecular weight) provides flexibility and processability, while the second fraction (lower density, higher molecular weight) maintains heat distortion temperature and mechanical strength, resolving the contradiction between flexibility and thermal stability
Solution Approach 2:
The patent employs parameter changes by systematically adjusting the density distribution, molecular weight distribution, and comonomer content across the two polyethylene fractions. By controlling these parameters within specific ranges (density 918-937 kg/m³ for first fraction, 905-918 kg/m³ for second fraction), the composition achieves optimal balance between flexibility and heat distortion temperature
2Ease of operation
If a polyethylene polymer is designed to have high flexibility, then the flexibility is improved, but the processability deteriorates
Solution Approach 1:
The patent uses composite materials by integrating two polyethylene fractions where the first fraction (higher density, lower molecular weight) contributes flexibility and the combined multimodal structure ensures good processability. The specific density and molecular weight distribution of the composite enables both flexibility and ease of extrusion and forming operations
Solution Approach 2:
The patent applies parameter changes by optimizing the molecular weight and density parameters of the polyethylene fractions. The first fraction with density 918-937 kg/m³ and lower molecular weight provides flexibility while maintaining processability, and the overall composition achieves a balance that enables feasible extrusion and forming processes
3Strength
If a polyethylene polymer is designed to have high abrasion resistance, then the mechanical properties are improved, but the flexibility deteriorates
Solution Approach 1:
The patent applies composite materials by combining two polyethylene fractions where the first fraction (higher density, lower molecular weight) provides abrasion resistance and mechanical strength, while the second fraction (lower density, higher molecular weight) maintains flexibility. This composite structure resolves the contradiction between durability and flexibility
Solution Approach 2:
The patent employs parameter changes by adjusting the density and molecular weight parameters within specific ranges. The first fraction with density 918-937 kg/m³ provides abrasion resistance, while the overall multimodal composition maintains flexibility through the presence of the second fraction with lower density and higher molecular weight
Data Source
Figure 1
AI summary
The present invention relates to a cable comprising a conductor surrounded by one or more layers, wherein at least one layer comprises a polymer composition comprising a multimodal copolymer of ethylene with one or more comonomers, to a process for producing the cable and to a polymer composition suitable as a cable layer material.