Peroxide Mixture for EVA Crosslinking
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Solution Overview
Problem
Current peroxides used in polymer crosslinking are thermally stable but prone to premature crosslinking during storage and processing, and require high temperatures for effective crosslinking, which complicates the production of polymers like ethylene vinyl acetate.
Innovation Solution
A peroxide mixture comprising tert-butyl peroxy-2-ethylhexanoate (TBPEH) and tert-butyl peroxy(2-ethylhexyl) carbonate (TBPEHC) with TBPEH at 5-15% and TBPEHC at 85-95% by weight, which maintains stability at room temperature and enables efficient crosslinking at lower temperatures (120-150°C).
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If thermally stable peroxides are used to prevent premature crosslinking during storage and processing, then storage stability and transport safety are improved, but crosslinking requires significantly higher temperatures which complicates the process
Solution Approach 1:
The patent combines two different peroxides (peroxide A and peroxide B) into a mixture where peroxide A provides thermal stability for storage and transport, while peroxide B enables crosslinking at lower temperatures. The synergistic effect of the mixture resolves the contradiction between storage stability and crosslinking temperature requirements.
Solution Approach 2:
The invention uses a composite peroxide system consisting of multiple peroxide components with different thermal decomposition characteristics. This composite approach allows the mixture to exhibit both high storage stability (from peroxide A) and low-temperature crosslinking capability (from peroxide B), eliminating the need to choose between conflicting requirements.
2Reliability
If peroxides are made sufficiently stable for compounding and storage at room temperature, then premature crosslinking during granulate storage and shaping is prevented, but crosslinking speed decreases requiring higher temperatures
Solution Approach 1:
The patent merges the advantages of two peroxides: peroxide A ensures processing reliability and prevents premature crosslinking during storage and compounding, while peroxide B provides fast crosslinking at lower temperatures. The combination achieves both high reliability and high productivity simultaneously.
Solution Approach 2:
The invention changes the thermal parameters of the peroxide system by using a mixture with different decomposition temperatures than the individual components would suggest. The mixture exhibits an onset temperature that is at least 10°C higher than peroxide A alone, yet maintains the crosslinking speed advantage of peroxide B, effectively decoupling storage stability from crosslinking speed.
3Productivity
If peroxides are designed for high crosslinking speed at low temperatures, then crosslinking efficiency is improved, but premature crosslinking occurs during storage and processing
Solution Approach 1:
The patent combines a stable peroxide (A) that prevents premature crosslinking with a reactive peroxide (B) that provides high crosslinking speed. The stable peroxide acts as a protective component that suppresses premature reactions, while the reactive peroxide ensures fast crosslinking when activated, resolving the contradiction between speed and stability.
Solution Approach 2:
Peroxide A acts as an intermediary that modulates the reactivity of peroxide B. It provides thermal stability during storage and processing, preventing premature crosslinking, while allowing peroxide B to function effectively at the appropriate time and temperature for rapid crosslinking.
4Reliability
If high temperatures are used to achieve effective crosslinking with stable peroxides, then crosslinking completeness is improved, but energy consumption increases and processing complexity increases
Solution Approach 1:
The patent combines peroxides with complementary thermal characteristics to achieve complete crosslinking at lower temperatures. Peroxide A provides stability while peroxide B enables efficient crosslinking at reduced temperatures, thereby achieving crosslinking completeness without the high energy consumption associated with high-temperature processing.
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 peroxide mixture prevents premature crosslinking during processing, achieves high crosslinking efficiency at lower temperatures, and allows for reduced peroxide dosages while maintaining processing reliability, particularly beneficial for ethylene vinyl acetate films in solar cell encapsulation.
Implementation Method 1
the decomposition temperature of the peroxide must inevitably be significantly exceeded
Implementation Method 2
In the peroxide crosslinking of polymers, such as polyolefins (LDPE, HDPE, LLDPE) or elastomers (EVA, EPDM, NBR, BR, SBR)
Implementation Method 3
They can also be mixed and processed with crosslinkable polymers, for example in a compounding process or in an extrusion process, without premature crosslinking occurring
Data Source
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AI summary
The invention relates to peroxide mixtures, and in particular peroxide mixtures that are suitable for cross-linking ethylene vinyl acetate in an accelerated manner.