Silane Catalyst Masterbatch Water Control for Scorch-Free Crosslinking
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Solution Overview
Problem
Existing polymer compositions face challenges in achieving scorch-free crosslinking during production due to high water content, leading to pre-crosslinked gels and reduced storage stability of catalyst masterbatches.
Innovation Solution
A polymer composition with a silane containing drying agent and a Brönstedt acid type silanol condensation catalyst having a water content of 0.1% or lower, blended into a catalyst masterbatch and evenly distributed within the base resin to control water absorption and ensure effective crosslinking without scorching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If water content is not controlled during manufacturing, then crosslinking reactions can proceed, but pre-crosslinked gels (scorch) form during production
Solution Approach 1:
The patent applies parameter changes by strictly controlling the water content parameter to 0.1% or lower in the catalyst system. This parameter control prevents premature crosslinking reactions during manufacturing while enabling effective crosslinking afterward, thereby resolving the contradiction between allowing crosslinking and preventing scorch.
Solution Approach 2:
The patent implements preliminary action by pre-drying the catalyst and silane-containing drying agent before mixing them with the base resin. This preliminary removal of water prevents crosslinking reactions from occurring during the manufacturing process, ensuring scorch-free production while maintaining the capability for effective crosslinking later.
2Stability of the object's composition
If water content is high in catalyst masterbatch, then crosslinking can occur, but storage stability decreases
Solution Approach 1:
The patent applies parameter changes by controlling the water content parameter to 0.1% or lower in the catalyst masterbatch. This strict parameter control maintains the masterbatch in a stable, non-crosslinked state during storage, preventing premature gelation while preserving the crosslinking capability for later use.
3Strength
If crosslinking is promoted during production, then mechanical strength improves, but pre-crosslinked gels form during manufacturing
Solution Approach 1:
The patent implements preliminary action by removing water from the catalyst and drying agents before manufacturing. This preliminary water removal prevents crosslinking reactions during production, ensuring the polymer remains processable while maintaining the potential for strong crosslinked structures to form after manufacturing under controlled conditions.
Solution Approach 2:
The patent applies the extraction principle by removing water from the system through drying the catalyst and silane-containing drying agent before mixing. This extraction of the water necessary for premature crosslinking allows manufacturing to proceed without gel formation, while the crosslinking capability remains intact for later activation.
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 solution enables excellent control of water content during manufacturing, maintaining scorch-free production and increased storage stability of the polymer article, while promoting desired crosslinking performance and producing a smooth cable surface.
Implementation Method 1
a silane containing drying agent and at least one silanol condensation catalyst, wherein each catalyst has a water content which is 0.1 % by weight or lower
Implementation Method 2
the crosslinking process may advantageously be carried out in the presence of acidic silanol condensation catalysts
Implementation Method 3
at least one silanol condensation catalyst, wherein each catalyst has a water content which is 0.1 % by weight or lower and is selected from: i) a compound of formula I ArSO3H (I) or a precursor thereof
Implementation Method 4
water, besides silane functionality and catalyst, is needed for silane hydrolysis and condensation
Data Source
AI summary
The present invention relates to a polymer composition,which is a silanol condensation catalyst masterbatch,comprises a matrix, comprising a silane containing drying agent, and at least one silanol condensation catalyst, wherein each catalyst has a water content which is 0.1 % by weight, or lower, and is selected from: i) a compound of formula I ArSO3 H (I) or a precursor thereof, wherein Ar is an 1 to 4 alkyl groups substituted aryl, wherein the aryl is phenyl or naphthyl; and wherein each alkyl group, independently, is a linear or branched alkyl with 10 to 30 carbons, wherein total number of carbons in the alkyl groups is 20 to 80 carbons; ii) a derivative of i) selected from the group consisting of an anhydride, an ester, an acetylate, an epoxyblocked ester and an amine salt thereof which is hydrolysable to the corresponding compound of formula I; and iii) a metal salt of i) wherein the metal ion is selected from the group consisting of copper, aluminum, tin and zinc; an article, for example, a coating, a wire or a cable, comprising the polymer composition, and process for producing an article.