Silane Crosslinkable Resin Composition Without Tin Catalyst Odor
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Solution Overview
Problem
Existing silane crosslinking methods using organic tin compounds as catalysts face issues with environmental hormone concerns, odor generation, and trade-offs between crosslinking rate and density, leading to manufacturability challenges and appearance defects.
Innovation Solution
A silane crosslinkable resin composition using a silanol condensation catalyst with a specific chemical structure represented by Formula (1) and a mass reduction rate of less than 10.0% under specified conditions, eliminating tin-containing catalysts and allowing for controlled crosslinking reactions without odor generation, resulting in high crosslinking density and excellent appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If organic tin compound is used as silanol condensation catalyst, then crosslinking rate and crosslinking density are improved, but environmental hormone action and safety concerns occur
Solution Approach 1:
The patent replaces the organic tin compound catalyst with an organic zinc compound catalyst, changing the chemical parameter of the catalyst system. This substitution maintains adequate crosslinking rate while eliminating environmental hormone action, as zinc compounds do not exhibit endocrine disruptive effects like tin compounds do.
Solution Approach 2:
The patent uses an organic zinc compound as a temporary catalyst that facilitates the silanol condensation reaction and then can be decomposed or removed. The zinc compound serves its catalytic function and can be replaced without long-term environmental persistence concerns, unlike tin compounds that accumulate in the environment.
2Productivity
If production temperature is increased to improve crosslinking rate, then crosslinking density increases, but odor generation and appearance defects occur
Solution Approach 1:
The patent changes the catalyst from organic tin compound to organic zinc compound, which has different thermal decomposition characteristics. The zinc-based catalyst allows for lower production temperatures to achieve adequate crosslinking rates, thereby suppressing odor generation and preventing appearance defects while maintaining acceptable crosslinking density.
Solution Approach 2:
The organic zinc compound acts as an intermediary catalyst that mediates the silanol condensation reaction at lower temperatures compared to tin compounds. It provides sufficient catalytic activity to drive the crosslinking reaction without requiring high temperature conditions that would cause odor and appearance problems.
3Object-generated harmful factors
If production temperature is decreased to suppress odor generation, then odor is suppressed, but crosslinking rate and crosslinking density reduce
Solution Approach 1:
The patent modifies the catalyst system from tin-based to zinc-based organic compounds, which changes the temperature-activity relationship. The zinc-based catalyst maintains sufficient crosslinking rate at lower production temperatures where odor generation is suppressed, effectively decoupling the trade-off between temperature, odor, and crosslinking rate.
Solution Approach 2:
The organic zinc compound provides localized catalytic activity at the molecular level that is sufficient to drive crosslinking at lower temperatures. The catalyst creates localized reaction zones with high effectiveness, allowing overall lower production temperatures while maintaining adequate crosslinking rate and density.
4Object-affected harmful factors
If organic sulfonic acid or zinc carboxylate is used as catalyst, then tin-containing catalysts are eliminated, but pungent odor is generated during crosslinking reaction
Solution Approach 1:
The patent selects specific organic zinc compounds with particular molecular structures and properties that differ from both tin compounds and zinc carboxylates. The chosen zinc-based catalyst eliminates environmental hormone action while having different volatility and decomposition characteristics that suppress pungent odor generation during the crosslinking reaction.
Solution Approach 2:
Instead of using traditional acid-based catalysts (organic sulfonic acid) or common zinc salts (zinc carboxylate) that generate odor, the patent inverts the approach by using organometallic zinc compounds with specific ligands that provide catalytic activity without the odor-generating properties of the traditional catalysts.
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 enables controlled crosslinking reactions with suppressed odor generation, producing silane crosslinked resin bodies with high crosslinking density and excellent manufacturability, addressing the limitations of traditional catalysts.
Implementation Method 1
a silane crosslinking method capable of easily crosslinking a silane crosslinkable resin composition with high productivity
Implementation Method 2
As a silanol condensation catalyst that causes or accelerates this condensation reaction, various compounds can be used
Implementation Method 3
it is necessary to perform the production process at a low temperature in order to suppress generation of odor
Data Source
AI summary
Provided are a silane crosslinkable resin composition containing at least one kind of silanol condensation catalyst represented by a specific formula and having a mass reduction rate of less than 10.0% when heated at 100° C. for 30 minutes, and not containing a tin-containing silanol condensation catalyst, and a silane crosslinked resin formed body and an electric wire using the silane crosslinkable resin composition.