Semiconductive Polyolefin Composition with Low-Filler Percolation

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Solution Overview

Problem

Existing semiconductive materials for power cables require high loadings of carbon black or graphene nanoparticles, leading to increased viscosity and processing difficulties, which adversely affect mechanical properties and production costs.

Innovation Solution

A semiconductive polyolefin composition comprising 80-99.5% olefin polymer base resin, 0.1-10% first carbonaceous structures, and 0.2-15% carbon black, with a combined filler loading of 0.3-15%, achieving an electrical percolation threshold of ≤5% for enhanced conductivity and processability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If high loadings of carbon black (30-50 wt.%) are used to achieve semiconductive properties, then electrical conductivity is improved, but viscosity increases and processability deteriorates

Engineering Contradiction:

Improveelectrical conductivityVSAvoidprocessability

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The invention changes the particle size parameter of carbon black from conventional sizes to ultrafine particles (D50: 0.03-0.1 μm). This parameter change allows achieving the same electrical conductivity at lower loadings (5-20 wt.%) because the ultrafine particles have higher specific surface area and can form conductive networks more efficiently, thus reducing viscosity and improving processability while maintaining conductivity

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention uses a composite approach by combining ultrafine carbon black particles with a polyolefin matrix and optional functional additives. This composite structure allows the ultrafine CB particles to disperse uniformly in the polymer matrix, creating efficient conductive pathways at lower loadings, thereby resolving the contradiction between conductivity and processability

Inventive Principle:

Principle #40Composite materials

2Reliability

If high structure carbon black (e.g., Ketjen Black) is used to reduce filler amount, then electrical conductivity is improved at lower loadings, but viscosity drastically increases

Engineering Contradiction:

Improveelectrical conductivityVSAvoidviscosity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The invention changes two key parameters: particle size (to ultrafine 0.03-0.1 μm) and structure level (to low structure with Iodine Number 150-400). This combination allows achieving conductivity at lower loadings without the viscosity penalty of high-structure CB, because the low structure prevents excessive particle aggregation and network formation that would increase viscosity

Inventive Principle:

Principle #35Parameter changes

3Reliability

If graphene nanoplatelets are used to increase conductivity, then electrical properties are improved, but filler loading requirements increase and processing becomes more difficult

Engineering Contradiction:

Improveelectrical conductivityVSAvoidprocessing

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The invention replaces expensive graphene nanoplatelets with ultrafine carbon black particles that are more cost-effective and easier to process. The ultrafine CB achieves comparable conductivity at lower loadings with better processability, making it a practical alternative to graphene for semiconductive cable compounds

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 achieves improved conductivity (≥1×10^-7 S/cm) with lower filler loadings, reducing viscosity and production costs while maintaining mechanical properties.

Implementation Method 1

a semiconductive polyolefin composition comprising... first carbonaceous structures... carbon black... achieving an electrical percolation threshold of ≤5% for enhanced conductivity

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentEP4195223B1Semiconductive polyolefin composition comprising carbonaceous structures, power cable comprising the same and use thereof

Publication Date: 2025.10.01 BOREALIS GMBH

AI summary

The invention relates to a semiconductive polyolefin composition comprising, (A) 80 to 99.5 wt.% of an olefin polymer base resin based on the total weight of the semiconductive polyolefin composition; (B) 0.1 to 10.0 wt.% of first carbonaceous structures based on the total weight of the semiconductive polyolefin composition; (C) 0.2 to 15.0 wt.% of carbon black and/or second carbonaceous structures based on the total weight of the semiconductive polyolefin composition; and (D) optionally additives; wherein the combined amount of components (B) and (C) is at least 0.3 wt.% and not more than 15.0 wt.% based on the total weight of the semiconductive polyolefin composition; and wherein the semiconductive polyolefin composition has an electrical percolation threshold of not more than 5 wt.% of the combined amount of components (B) and (C) dispersed in the olefin polymer base resin (A), the electrical percolation threshold being defined as the critical concentration in wt.% of the components (B) and (C) in the olefin polymer base resin (A) where an exponential increase in electrical conductivity is observed; wherein the polyolefin composition has a conductivity of at least 1·10-7 S/cm determined according to Broadband Dielectric Spectroscopy for a percolation threshold of 1.0 wt.% or lower and 2-point electrical measurements for a percolation threshold of more than 1.0 wt.%; and wherein components (A) to (D) add up to 100 wt.%.