BR112020001937B1 - RETICULABLE COMPOSITION, JACKET LAYER FOR A COATED CONDUCTOR, AND COATED CONDUCTOR - Google Patents

Abstract

It is an insulation layer or jacket for a coated conductor that is composed of (A) a cross-linked silane functional polyolefin, (B) a filler composed of more than 50% by weight silica, based on the total weight of the filler, (C) a silicone-containing polymer selected from the group consisting of linear reactive silicone-containing polymers, non-reactive linear silicone-containing polymers, and branched non-reactive silicone-containing polymers, and (D) from 0.00% in weight to 20% by weight of a silanol condensation catalyst, based on the total weight of the insulation layer or coating.

Description

FIELD OF DISCLOSURE

[001] The present invention relates to moisture curable compositions. In one aspect, the disclosure relates to moisture curable compositions having high resistance to wet electrical insulation and flame retardancy, while in another aspect, the disclosure relates to insulation or jacketing layers for wires and cables comprising a moisture curable composition. moisture and coated conductors, including the same.

BACKGROUND

[002] Moisture-curable compositions containing a silane-functionalized polyolefin (e.g., a silane-grafted polyolefin) are often used to form coatings, and particularly insulation or jacketing layers, for wires and cables. To improve the flame retardancy of the compositions, a flame retardant filler or combination of fillers is added. Flame retardant filler compounds generally decompose at elevated temperatures to release or absorb heat. For example, metal hydrates and other halogen-free flame retardant fillers release inert gas and absorb energy through an endothermic decomposition reaction when exposed to high temperatures. However, flame retardant compositions utilizing these halogen-free filler compounds that decompose at elevated temperatures tend to have low wet electrical insulation resistance.

[003] Silica was also considered as a flame retardant filler. However, because silica does not undergo an endothermic decomposition reaction, silica is generally only used in small quantities. Accordingly, the art recognizes the need for flame retardant compositions that use silica as the primary flame retardant filler in moisture curable compositions.

SUMMARY

[004] The disclosure provides a crosslinkable composition for an insulation layer or jacket for a coated conductor. In one embodiment, the crosslinkable composition comprises (A) a crosslinked silane functionalized polyolefin; (B) a charge comprising more than 50% by weight silica, based on the total weight of the charge; (C) a silicone-containing polymer selected from the group consisting of silicone-containing reactive linear polymers, silicone-containing non-reactive linear polymers, and silicone-containing non-reactive branched polymers; and (D) from 0.00% by weight to 20% by weight of a silanol condensation catalyst, based on the total weight of the crosslinkable composition.

[005] In another embodiment, the disclosure provides an insulation layer or jacket for a coated conductor. In one embodiment, the insulation or jacketing layer comprises (A) a cross-linked silane-functionalized polyolefin; (B) a charge comprising more than 50% by weight silica, based on the total weight of the charge; (C) a silicone-containing polymer selected from the group consisting of reactive silicone-containing linear polymers, non-reactive silicone-containing linear polymers, and non-reactive silicone-containing branched polymers; and (D) from 0.00% by weight to 20% by weight of a silanol condensation catalyst, based on the total weight of the insulation layer.

[006] In another embodiment, the disclosure provides a coated conductor. In one embodiment, the coated conductor comprises a conductor and a coating on the conductor, wherein the coating comprises (A) a cross-linked silane-functionalized polyolefin, (B) a filler comprising greater than 50% by weight silica, based on the total weight of the filler, (C) a silicone-containing polymer selected from the group consisting of linear reactive silicone-containing polymers, non-reactive linear silicone-containing polymers, and non-reactive branched silicone-containing polymers, and (D) of 0. 00% by weight to 20% by weight of a silanol condensation catalyst, based on the total weight of the coating.

DEFINITIONS AND TEST METHODS

[007] Any reference to the Periodic Table of Elements is as published by CRC Press, Inc., 1990 to 1991. Reference is made to a group of elements in that table by the new notation for group numbering.

[008] For purposes of patent practice in the United States, the content of any referenced patent, patent application, or publication is incorporated by reference in its entirety (or its equivalent U.S. version is incorporated by reference) especially with with respect to the disclosure of definitions (to the extent not inconsistent with any definitions specifically provided in this disclosure) and general knowledge of the art.

[009] The numerical ranges disclosed in this document include all values from the lowest value to the highest value, inclusive. For ranges that contain explicit values (e.g., 1 or 2, or 3 to 5, or 6, or 7), any subrange between any two explicit values is included (e.g., 1 to 2; 2 to 6; 5 to 7; 3 to 7; 5 to 6; etc.).

[0010] Unless otherwise indicated, implied from the context, or customary in the art, all parts and percentages are based on weight and all test methods are current as of the filing date of this disclosure and all test methods are current as of the filing date of this disclosure.

[0011] “Alkyl” and “alkyl group” refer to a linear, cyclic or branched saturated hydrocarbon group. “Aryl group" refers to an aromatic substituent that may be a single aromatic ring or multiple aromatic rings that are fused, covalently bonded, or bonded to a common group such as a methylene or ethylene moiety. The ring (or rings) aromatic includes phenyl, naphthyl, anthracenyl and biphenyl, among others. In particular embodiments, aryls have between 1 and 200 carbon atoms, between 1 and 50 carbon atoms or between 1 and 20 carbon atoms.

[0012] “Alpha-olefin”, “α-olefin” and similar terms refer to a hydrocarbon molecule or a substituted hydrocarbon molecule (i.e., a hydrocarbon molecule comprising one or more atoms other than hydrogen and carbon, for example, halogen, oxygen, nitrogen, etc.), the hydrocarbon molecule comprising (i) only one ethylenic unsaturation, this unsaturation being located between the first and second carbon atoms, and (ii) at least 2 atoms of carbon, preferably from 3 to 20 carbon atoms, in some cases, preferably from 4 to 10 carbon atoms and, in other cases, preferably from 4 to 8 carbon atoms. Non-limiting examples of α-olefins from which elastomers are prepared include ethylene, propylene, 1-butene, 1-pentene, 1-hexene, 1-octene, 1-dodecene and mixtures of two or more of these monomers.

[0013] “Mix”, “polymer blend” and similar terms indicate a composition of two or more polymers. Such a mixture may or may not be miscible. Such a mixture may or may not be phase separated. This mixture may or may not contain one or more domain configurations, as determined from transmission electron spectroscopy, light scattering, x-ray scattering, and any other method used to measure and/or identify domain configurations. Blends are not laminates, but one or more layers of a laminate may contain a blend.

[0014] "Carboxylate" refers to a carboxylic acid salt or ester.

[0015] “Composition”, as used herein, includes a mixture of materials comprising the composition, as well as reaction products and decomposition products formed from the composition materials.

[0016] The terms “which comprises”, “which includes”, “which has” and their derivatives do not exclude the presence of any additional component, step or procedure regardless of whether or not they are specifically disclosed. For the avoidance of doubt, all compositions claimed through the use of the term “comprising” may include any additive, adjuvant or additional compound, whether polymeric or not, unless otherwise stated. In contrast, the term “consist essentially of ” excludes from the scope of any subsequent citation any other component, step or procedure except those that are not essential to operability The term “consist of” excludes any component, step or procedure not specifically listed. otherwise, it refers to the listed members individually as well as in any combination. Use of the singular includes use of the plural and vice versa.

[0017] A "conductor" is an elongated shaped element (wire, cable, optical fiber) to transfer energy at any voltage (DC, AC or transient). The conductor is typically at least one metal wire or at least one metal cable (such as aluminum or copper), but may be optical fiber. The conductor may be a single cable or a plurality of cables connected together (i.e., a cable core or a core).

[0018] “Cross-linkable”, “curable” and similar terms mean that the polymer, before or after forming into an article, is not cured or cross-linked and has not been subjected to or exposed to treatment that has induced substantial cross-linking, although the polymer comprises additive (or additives) or functionality that will effect substantial cross-linking upon subjection or exposure to such treatment (e.g., exposure to water).

[0019] “Cross-linked” and similar terms mean that the polymer composition, before or after being formed into an article, has xylene or decalin extractables less than or equal to 90 weight percent (i.e., greater than or equal to 10 percent by weight of gel content).

[0020] "Cured" and similar terms mean that the polymer, before or after being formed into an article, has been subjected to or exposed to a treatment that induced cross-linking.

[0021] Density is measured according to the ASTM D792 standard, Method B. The result is recorded in grams (g) per cubic centimeter (g/cm3).

[0022] Dynamic viscosity is the resistance of a fluid to shear flows and is reported in Pa•s (pascals per second), mPa•s (millipascals per second) or MPa•s (megapascals per second). The shear viscosity is calculated by , on what is the shear viscosity measured in Pascal•seconds, is the shear stress measured in Pascals, and is the shear rate, measured in reciprocal seconds. For purposes of this disclosure, dynamic viscosity is measured in accordance with ASTM D445.

[0023] An "ethylene/α-olefin polymer" is a polymer that contains a majority amount of polymerized ethylene, based on the weight of the polymer, and one or more α-olefin comonomers.

[0024] An "ethylene-based polymer", "ethylene polymer" or "polyethylene" is a polymer that contains 50% or more by weight, or a majority amount of polymerized ethylene based on the weight of the polymer and, optionally, may comprise one or more comonomers. Suitable comonomers include, but are not limited to) alpha-olefins and unsaturated esters. Suitable unsaturated esters include alkyl acyrylates, alkyl methacrylates and vinyl carboxylates. Suitable non-limiting examples of acrylates and methacrylates include ethyl acrylate, methyl acrylate, methyl methacrylate, t-butyl acrylate, n-butyl acrylate, n-butyl methacrylate and 2-ethylhexyl acrylate. Suitable non-limiting examples of vinyl carboxylate include vinyl acetate, vinyl propionate and vinyl butanoate. The generic term "ethylene-based polymer" thus includes ethylene homopolymer and ethylene interpolymer. The terms "ethylene-based polymer" and "polyethylene" are used interchangeably. Non-limiting examples of ethylene-based polymer (polyethylene) include low-density polyethylene (LDPE) and linear polyethylene. Non-limiting examples of linear polyethylene include linear low density polyethylene (LLDPE), ultra-low density polyethylene (ULDPE), very low density polyethylene (VLDPE), multi-component ethylene-based copolymer (EPE), multi-block copolymers of ethylene/α-olefin (also known as olefin block copolymers (OBC)), single-site catalyzed linear low-density polyethylene (m-LLDPE), substantially linear or linear plastomers/elastomers, medium-density polyethylene (MDPE), and high-density polyethylene (HDPE). Generally, polyethylene can be produced in gas-phase fluidized bed reactors, liquid-phase slurry process reactors, or liquid-phase solution process reactors, with the use of a heterogeneous catalytic system, such as a Ziegler-catalyst. Natta, a homogeneous catalytic system, comprising ligand structures and Group 4 transition metals, such as metallocene, non-metallocene-centered metal, heteroaryl, heterovalent aryloxyether, phosphinimine and the like. Combinations of heterogeneous and/or homogeneous catalysts can also be used in either single-reactor or dual-reactor configurations. Polyethylene can also be produced in a high-pressure reactor without a catalyst.

[0025] “Functional group” and similar terms refer to a chemical moiety or group of atoms responsible for giving a particular compound its characteristic reactions. Non-limiting examples of functional groups include heteroatom-containing moieties, oxygen-containing moieties (e.g., alcohol, aldehyde, ester, ether, ketone, and peroxide groups), and nitrogen-containing moieties (e.g., amide, amine, azo, imide groups). , imine, nitrate, nitrile and nitrite).

[0026] The horizontal burn test is administered in accordance with UL-2556. A burner is adjusted at a 20° angle to the horizontal of the sample (14 AWG copper wire with 0.76 mm (30 mil) polymer layer/wall thickness). A single flame is applied to the middle of the sample for 30 seconds. The sample fails when the cotton ignites (reported in seconds) or the length of the charcoal is greater than 100 mm.

[0027] "Hydrolyzable silane group" and similar terms mean a silane group that will react with water. These include alkoxysilane groups on monomers or polymers that can hydrolyze to produce silanol groups, which in turn can condense to cross-link the monomers or polymers.

[0028] “Interpolymer”, as used herein, refers to polymers prepared by the polymerization of at least two different types of monomers. The generic term interpolymer thus includes copolymers (used to refer to polymers prepared from two different types of monomers) and polymers prepared from more than two different types of monomers.

[0029] Kinematic viscosity is the ratio between the shear viscosity and the density of a fluid and is reported in cm2/s (square centimeters per second, St (stokes) or cSt (centistokes)). For the purposes of this specification, kinematic viscosity is measured at 40 ° C using a Brookfield viscometer in accordance with ASTM D 445 or.

[0030] The average particle size, or D50, is the particle diameter in which 50% of the particles have a diameter less than or equal to D50 and 50% of the particles have a diameter greater than D50.

[0031] Melt index (MI) measurement for polyethylene is performed in accordance with ASTM D1238, Condition 190 °C/2.16 kg (kg) weight, formerly known as "Condition E" and also known as I2 , and is reported in grams eluted per 10 minutes.

[0032] "Metals" includes all elements listed as metals in the Periodic Table of Elements, including Li, Be, Na, Mg, Al, K, Ca, Sc, Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Ga, Rb, Sr, Y, Zr, Nb, Mo, Tc, Ru, Rh, Pd, Ag, Cd, In, Sn, Cs, Ba, La, Hf, Ta, W, Re, Os, Ir, Pt, Au, Hg, Tl, Pb, Bi, Po, Fr, Ra, Ac, Rf, Db, Sg, Bh, Hs, Mt, Ds, Rg, and Cn, as well as the lanthanides and actinides.

[0033] "Metal-free", "metal-free filler" or "metal-free composition" is a filler or composition that contains 0% by weight or greater than 0% by weight or 0.05% by weight or 0.1% by weight or less than 0.15% by weight, or less than 0.2% by weight, or less than 0.3% by weight, or less than 0.4% by weight, or less than 0.5% by weight weight of metals by weight.

[0034] “Moisture curable” and similar terms mean that the composition of this invention will cure, that is, crosslink, upon exposure to water. Moisture curing can be with or without the aid of a crosslinking catalyst (curing catalyst). silanol condensation), promoter, etc.

[0035] A “polymer” is a polymeric compound prepared by polymerizing monomers of the same or different types. The generic term polymer thus encompasses the term “homopolymer” (used to refer to polymers prepared from only a type of monomer, with the understanding that trace amounts of impurities may be incorporated into the polymer structure) and the term "interpolymer", which includes copolymers (used to refer to polymers prepared from two different types of monomers), terpolymers (used to refer to polymers prepared from three different types of monomers) and polymers prepared from more than three different types of monomers. Trace amounts of impurities, for example catalyst residues, may be incorporated into the polymer and/or within the polymer. This also covers all forms of copolymer, e.g. random, block, etc. The terms “ethylene/α-olefin polymer” and “propylene/α-olefin polymer” are indicative of a copolymer as described above, prepared from polymerization of ethylene or propylene, respectively, and one or more α-comonomers. additional polymerizable olefins. It is noted that although a polymer is often referred to as being “produced from” one or more specified monomers, “based on” a specified monomer or type of monomer, “containing” a specified monomer content, or similar, in this context, the term “monomer” is understood to refer to the polymerized remainder of the specified monomer and not to the unpolymerized species. In general, polymers herein are referred to as being based on “units” that are the polymerized form of a corresponding monomer.

[0036] “Polyolefin” and similar terms mean a polymer derived from simple olefinic monomers, for example, ethylene, propylene, 1-butene, 1-hexene, 1-octene and the like. Olefinic monomers can be substituted or unsubstituted, and if substituted, the substituents can vary widely.

[0037] A "propylene-based polymer", "propylene polymer" or "polypropylene" is a polymer that contains 50% or more by weight, or a majority amount of polymerized propylene based on the weight of the polymer and, optionally, may comprise one or more comonomers. The generic term "propylene-based polymer" thus includes propylene homopolymer and propylene interpolymer.

[0038] "Ambient temperature" means 25 °C +/- 4 °C.

[0039] A "sheath" is a generic term and, when used in relation to cables, includes coverings or insulation layers, jacket layers, and the like.

[0040] Specific gravity is the ratio between the density of a substance and the density of a pattern. In the case of a liquid, the default is water. Specific gravity is a dimensionless quantity and is measured according to ASTM D1298.

[0041] The weight average molecular weight (Mw) is defined as the weight average molecular weight of the polymer, and the number average molecular weight (Mn) is defined as the number average molecular weight of the polymer. The polydispersity index is measured according to the following technique: Polymers are analyzed by gel permeation chromatography (GPC) on a Waters 150 °C temperature chromatographic unit equipped with three linear mixed-bed columns (Polymer Laboratories (10 particle size microns)) which operates at a system temperature of 140 °C. The solvent is 1,2,4-trichlorobenzene from which about 0.5% by weight of sample solutions are prepared for injection. The flow rate is 1.0 milliliter/minute (mm/min) and the injection size is 100 microliters (μL). Molecular weight determination is deduced using rigid molecular weight distribution polystyrene standards (from Polymer Laboratories) in conjunction with molecular elution volumes. Equivalent polyethylene molecular weights are determined using Mark-Houwink coefficients appropriate for polyethylene and polystyrene (as described by Williams and Ward in Journal of Polymer Science, Polymer Letters, Volume 6, (621) 1968, incorporated herein for reference) to derive the equation: Mpolyethylene = (a)(Mpolystyrene)b In this equation, a = 0.4316 and b = 1.0.

[0042] The weight-average molecular weight, Mw, is calculated in the usual way, according to the formula: Mw = E(wi) (Mi) where wi and Mi are the weight fraction and molecular weight, respectively, of the i-th fraction eluting from the GPC column. Generally, the Mw of the ethylene polymer ranges from 42,000 to 64,000, preferably from 44,000 to 61,000, and more preferably from 46,000 to 55,000.

[0043] Wet insulation resistance (IR) is typically performed on a wound moisture-cured coated conductor (14 AWG copper wire with 0.76 millimeter (30 mil) polymer layer/wall thickness) of which 3.048 meters ( 10 feet) long are immersed in an electric water bath at 90 °C. Wires are connected to a megger so that water is one electrode and the wire conductor is the other. In this way, the direct current (DC) electrical resistance of the insulation layer is measured with 500 V applied. The initial measurement is taken after 6 to 24 hours of submersion, and all subsequent measurements are performed at a frequency of 7 days for a period of up to 12 weeks while the sample is aged below 600 V alternating current (AC). If, before weeks 10 to 12, the average resistance measured for a 3.05 meter (10 foot) long wire is below 1,000 MOhms, the samples are considered to have failed the test and labeled “Failed”. For samples exhibiting resistance greater than 1,000 MOhms prior to weeks 10-12, the wet insulation resistance ratio is calculated by dividing the average RI recorded in weeks 10-12 by the average RI recorded in weeks 6-8.

[0044] A “wire” is a single strand of conductive metal, for example, copper or aluminum, or a single strand of optical fiber.

DETAILED DESCRIPTION

[0045] In one embodiment, the disclosure provides a crosslinkable composition for use as a jacket layer for a coated conductor. As used herein, "shirt layer" encompasses the insulation layer. In one embodiment, the jacket layer is an insulation layer.

[0046] In one embodiment, the disclosure provides a crosslinkable composition for an insulation layer or jacket for a coated conductor, the crosslinkable composition comprising (A) a silane functionalized polyolefin, (B) a filler comprising greater than 50% by weight of silica, based on the total weight of the filler, (C) a silicone-containing polymer, and (D) from 0.00% by weight to 20% by weight of a silanol condensation catalyst, based on the total weight of the composition crosslinkable.

[0047] In one embodiment, the disclosure provides an insulation or jacketing layer for a coated conductor comprising (A) a cross-linked silane-functionalized polyolefin, (B) a filler comprising greater than 50% by weight silica, based on weight total charge, (C) a silicone-containing polymer, and (D) from 0.00% by weight to 20% by weight of a silanol condensation catalyst, based on the total weight of the insulation layer or jacket.

(A) ACID-FUNCTIONALIZED POLYOLEFINE

[0048] The crosslinkable composition includes a silane-functionalized polyolefin.

[0049] In one embodiment, the composition contains 0.1% by weight, or 0.3% by weight, or 0.5% by weight, or 0.8% by weight, or 1.0% by weight, or 1.2% by weight, or 1.5% by weight to 1.8% by weight, or 2.0% by weight, or 2.3% by weight, or 2.5% by weight, or 3, 0% by weight, or 3.5% by weight, or 4.0% by weight, or 4.5% by weight, or 5.0% by weight silane, based on the total weight of the silane-functionalized polyolefin.

[0050] In one embodiment, the silane functionalized polyolefin has a density of 0.850 g/cm3 or 0.860 g/cm3 or 0.875 g/cm3 or 0.890 g/cm3 or 0.900 g/cm3 to 0.910 g/cm3 or 0.915 g/cm3 or 0.920 g/cm3 or 0.930 g/cm3 or 0.940 g/cm3 or 0.950 g/cm3 or 0.960 g/cm3 or 0.965 g/cm3, as measured in accordance with ASTM D-792.

[0051] In one embodiment, the silane-functionalized polyolefin is an alpha-olefin/silane copolymer or a silane-grafted polyolefin (Si-g-PO).

[0052] An α-olefin/silane copolymer is formed from the copolymerization of an α-olefin (such as ethylene) and a hydrolyzable silane monomer (such as a vinylsilane monomer). In one embodiment, the alpha-olefin/silane copolymer in an ethylene/silane copolymer prepared by copolymerization of ethylene, a hydrolyzable silane monomer, and optionally an unsaturated ester. The preparation of ethylene/silane copolymers is described, for example, in USP 3,225,018 and USP 4,574,133, each incorporated herein by reference.

[0053] A silane-grafted polyolefin (Si-g-PO) is formed by grafting a hydrolyzable silane monomer (such as a vinylsilane monomer) onto the backbone of a basic polyolefin (such as polyethylene). In one embodiment, grafting occurs in the presence of a free radical generator, such as a peroxide. The hydrolyzable silane monomer can be grafted onto the backbone of the base polyolefin before incorporating or compounding the Si-g-PO into a final article or simultaneously with extrusion of the composition to form a final article. For example, in one embodiment, the Si-g-PO is formed before the Si-g-PO is compounded with (B) filler, (C) silicone-containing polymer, (D) silanol condensation catalyst, and other components optional. In another embodiment, Si-g-PO is formed by the composition of a polyolefin, hydrolyzable silane monomer and catalyst/tracing agent together with (B) filler, (C) silicone-containing polymer, (D) silicone condensation catalyst silanol, and other optional components.

[0054] The base polyolefin for a Si-g-PO can be an ethylene-based or propylene-based polymer. In one embodiment, the base polyolefin is an ethylene-based polymer, resulting in a silane-grafted ethylene-based polymer (Si-g-PE). Non-limiting examples of suitable ethylene-based polymer include ethylene homopolymer and ethylene interpolymers that contain one or more polymerizable comonomers, such as an unsaturated ester and/or an alpha-olefin.

[0055] The hydrolyzable silane monomer used to make an alpha-olefin/silane copolymer or a Si-g-PO is a silane-containing monomer that effectively copolymerizes with an alpha-olefin (e.g., ethylene) to form a silane copolymer. alpha-olefin/silane (e.g., an ethylene/silane copolymer) or grafting and cross-linking an alpha-olefin polymer (e.g., a polyolefin) to form a Si-g-PO. Exemplary hydrolyzable silane monomers are those with the following structure: wherein R' is a hydrogen atom or methyl group; x and y are 0 or 1 with the exception that when x is 1, y is 1; n is an integer from 1 to 12 inclusive, preferably 1 to 4, and each R'', independently, is a hydrolyzable organic group, such as an alkoxy group having from 1 to 12 carbon atoms (e.g. methoxy, ethoxy, butoxy), aryloxy group (e.g., phenoxy), araloxy group (e.g., benzyloxy), aliphatic acyloxy group having 1 to 12 carbon atoms (e.g., formyloxy, acetyloxy, propanoyloxy), amino groups or substituted amino (alkylamine, arylamine), or a lower alkyl group having from 1 to 6 carbon atoms inclusive, with the proviso that not more than one of the three groups R” is an alkyl.

[0056] Non-limiting examples of suitable hydrolyzable silane monomer include silanes comprising an ethylenically unsaturated hydrocarbyl group, such as a vinyl, allyl, isopropenyl, butenyl, cyclohexenyl or gamma (meth) allyl acryloxy group, and a hydrolysable group , such as, for example, a hydrocarbyloxy, hydrocarbonyloxy or hydrocarbylamino group. Examples of hydrolyzable groups include methoxy, ethoxy, formyloxy, acetoxy, propionyloxy and alkyl or arylamine group.

[0057] In one embodiment, the hydrolyzable silane monomer is an unsaturated alkoxy silane, such as vinyl trimethoxy silane (VTMS), vinyl trethoxy silane, vinyl triacetoxy silane, gamma-(meth)acryloxy, propyl trimethoxy -silane and mixtures of these silanes.

[0058] Non-limiting examples of suitable unsaturated esters used to make an alpha-olefin/silane copolymer include alkyl acrylate, alkyl methacrylate or vinyl carboxylate. Non-limiting examples of suitable alkyl groups include methyl, ethyl, n-propyl, i-propyl, n-butyl, t-butyl, etc. In one embodiment, the alkyl group has from 1 or 2 to 4 or 8 carbon atoms. Examples of suitable non-limiting alkyl acrylates include ethyl acrylate, methyl acrylate, t-butyl acrylate, n-butyl acrylate, 2-ethylhexyl acrylate. Non-limiting examples of suitable alkyl methacrylate include methyl methacrylate and n-butyl methacrylate. In one embodiment, the carboxylate group has 2 to 5 or 6 or 8 carbon atoms. Non-limiting examples of suitable vinyl carboxylates include vinyl acetate, vinyl propionate and vinyl butanoate.

[0059] In one embodiment, the silane-functionalized polyolefin is a silane-functionalized polyethylene. A "silane-functionalized polyethylene" is a polymer that contains silane and equal to or greater than 50% by weight, or a majority amount, of polymerized ethylene, based on the total weight of the polymer.

[0060] In one embodiment, the silane functionalized polyethylene contains (i) 50% by weight, or 55% by weight, or 60% by weight, or 65% by weight, or 70% by weight, or 80% by weight weight, or 90% by weight, or 95% by weight, or 97% by weight, or 98% by weight, or 99% by weight, or less than 100% by weight of ethylene and (ii) 0.1% by weight weight, or 0.3% by weight, or 0.5% by weight, or 0.8% by weight, or 1.0% by weight, or 1.2% by weight, or 1.5% by weight to 1.8% by weight, or 2.0% by weight, 2.3% by weight, or 2.5% by weight, or 3.0% by weight, or 3.5% by weight, or 4.0% by weight, or 4.5% by weight, or 5.0% by weight silane, based on the total weight of the silane-functionalized polyethylene.

[0061] In one embodiment, the silane-functionalized polyethylene has a melt index (MI) of 0.1 g/10 min, or 0.5 g/10 min, or 1.0 g/10 min, or 2. 0 g/10 min, or 3 g/10 min, or 5 g/10 min, or 8 g/10 min, or 10 g/10 min, or 15 g/10 min, or 20 g/10 min, or 25 g/10 min, or 30 g/10 min, or 40 g/10 min, or 45 g/10 min, or 50 g/10 min, or 55 g/10 min, or 60 g/10 min, or 65 g /10 min, or 70 g/10 min, or 75 g/10 min, or 80 g/10 min, or 85 g/10 min, or 90 g/10 min, measured in accordance with ASTM D1238 (190 °C /2.16 kg).

[0062] In one embodiment, the silane-functionalized polyethylene is an ethylene/silane copolymer.

[0063] In one embodiment, the ethylene/silane copolymer contains ethylene and the hydrolyzable silane monomer as the only monomeric units.

[0064] In one embodiment, the ethylene/silane copolymer optionally includes a C3, or C4 to C6, or C8, or C10, or C12, or C16, or C18 or C20 α-olefin; an unsaturated ester; and combinations thereof. In one embodiment, the ethylene/silane copolymer is an ethylene/unsaturated ester/silane reactor copolymer.

[0065] Non-limiting examples of suitable ethylene/silane copolymer include SI-LINK™ DFDA-5451 NT and SI-LINK™ AC DFDB-5451 NT, each available from The Dow Chemical Company, Midland, Michigan.

[0066] The ethylene/silane reactor copolymer may comprise two or more embodiments disclosed herein.

[0067] In one embodiment, the silane-functionalized polyethylene is a Si-g-PE. The base ethylene-based polymer for Si-g-PE includes 50% by weight, or 55% by weight, or 60% by weight, or 65% by weight, or 70% by weight, or 80% by weight , or 90% by weight, or 95% by weight, or 97% by weight, or 98% by weight, or 99% by weight, or 100% by weight ethylene, based on the weight of the base ethylene-based polymer .

[0068] In one embodiment, the base ethylene-based polymer for Si-g-PE has a density of 0.850 g/cm3 or 0.860 g/cm3 or 0.875 g/cm3 or 0.890 g/cm3 or 0.900 g/cm3 or 0.910 g/cm3 or 0.915 g/cm3 or 0.920 g/cm3 or 0.930 g/cm3 or 0.940 g/cm3 or 0.950 g/cm3 or 0.960 g/cm3 or 0.965 g/cm3, as measured in accordance with ASTM D-792 .

[0069] In one embodiment, the base ethylene-based polymer for Si-g-PE has a melt index (MI) of 0.1 g/10 min, or 0.5 g/10 min, or 1. 0 g/10 min, or 2 g/10 min, or 3 g/10 min, or 5 g/10 min, or 8 g/10 min, or 10 g/10 min, or 15 g/10 min, or 20 g/10 min, or 25 g/10 min, or 30 g/10 min to 40 g/10 min, or 45 g/10 min, or 50 g/10 min, or 55 g/10 min, or 60 g/ 10 min, or 65 g/10 min, or 70 g/10 min, or 75 g/10 min, or 80 g/10 min, or 85 g/10 min, or 90 g/10 min, measured according to ASTM D1238 (190°C/2.16kg).

[0070] In one embodiment, the ethylene-based polymer for Si-g-PE is a homogeneous polymer. Homogeneous ethylene-based polymers have a polydispersity index (Mw/Mn or MWD) in the range of 1.5 to 3.5 and an essentially uniform comonomer distribution, and are characterized by a single, relatively low melting point, as measured by differential scanning calorimetry (DSC). Substantially linear ethylene copolymers (SLEP) are homogeneous ethylene-based polymers.

[0071] As used herein, "substantially linear" means that the bulk polymer is replaced, on average, by about 0.01 long-chain branches/1,000 total carbons (including backbone carbons and branches) or about from 0.05 long-chain branches/1,000 total carbons (including backbone and branch carbons), or about 0.3 long-chain branches/1,000 total carbons (including backbone and branch carbons) to about 1 long-chain branch/1000 total carbons (including backbone carbons and branches), or about 3 long-chain branches/1000 total carbons (including backbone carbons and branches).

[0072] "Long chain branches" or "long chain branching" (LCB) means a chain length of at least one (1) carbon less than the number of carbons in the comonomer. For example, an ethylene/1-octene SLEP has backbone structures with long-chain branches at least seven (7) carbons long and an ethylene/l-hexene SLEP has long-chain branches at least five (5) carbons long. long carbons. LCB can be distinguished using 13C nuclear magnetic resonance (NMR) spectroscopy to some extent, for example, for ethylene homopolymers, they can be quantified using the Randall method (Rev. Macromol. Chem. Phys., C29 (2 & 3). Document USP 4,500,648 teaches that the frequency of LCB can be represented by the equation LCB = b/Mw, where b is the weight average number of LCB per molecule and Mw is the weight average molecular weight. Molecular weight averages and LCB characteristics are determined by gel permeation chromatography (GPC) and intrinsic viscosity methods.

[0073] SLEPs and their preparation method are described in more detail in documents USP 5,741,858 and USP 5,986,028.

[0074] In one embodiment, the base ethylene-based polymer for Si-g-PE is an ethylene/unsaturated ester copolymer. The unsaturated ester may be any unsaturated ester disclosed herein, such as ethyl acrylate. In one embodiment, the base ethylene-based polymer for Si-g-PE is an ethylene/ethyl acrylate (EEA) copolymer.

[0075] In one embodiment, the base ethylene-based polymer for Si-g-PE is an ethylene/α-olefin copolymer. α-olefin contains 3, or 4 to 6, or 8, or 10, or 12, or 16, or 18 or 20 carbon atoms. Non-limiting examples of suitable α-olefin include propylene, butene, hexene and octene. In one embodiment, the ethylene-based copolymer is an ethylene/octene copolymer. When the ethylene-based copolymer is an ethylene/α-olefin copolymer, the Si-g-PO is a silane-grafted ethylene/α-olefin copolymer.

[0076] Non-limiting examples of suitable ethylene/alpha-olefin copolymers useful as a base ethylene-based polymer for Si-g-PE include ENGAGE™ and INFUSE™ resins, available from Dow Chemical Company.

[0077] In one embodiment, the silane-functionalized polyolefin is a silane-grafted ethylene/C48-C84 alpha-olefin polymer that has one or both of the following properties: (i) a density of 0.850 g/cm3, or 0.860 g /cm3, or 0.875 g/cm3, 0.890 g/cm3 to 0.900 g/cm3, or 0.910 g/cm3, or 0.915 g/cm3, or 0.920 g/cm3, or 0.925 g/cm3, or 0.930 g/cm3, or 0.935 g/cm3; and (ii) a melt index of 0.1 g/10 min, or 0.5 g/10 min, or 1.0 g/10 min, or 2 g/10 min, or 5 g/10 min, or 8 g/10 min, or 10 g/10 min, or 15 g/10 min, or 20 g/10 min, or 25 g/10 min, or 30 g/10 min to 30 g/10 min, or 35 g /10 min, or 45 g/10 min, or 50 g/10 min, or 55 g/10 min, or 60 g/10 min, or 65 g/10 min, or 70 g/10 min, or 75 g/ 10 min, or 80 g/10 min, or 85 g/10 min, or 90 g/10 min; In one embodiment, the silane-grafted ethylene-based polymer has both properties (i) to (ii).

[0078] The silane functionalized polyolefin is present in an amount of 10% by weight, or 20% by weight, or 30% by weight, or 40% by weight, or 50% by weight, or 60% by weight, or 80% by weight, or 90% by weight, or 95% by weight, based on the total weight of the crosslinkable composition.

[0079] Mixtures of silane-functionalized polyolefins can also be used and the silane-functionalized polyolefin (or polyolefins) can be diluted with one or more other polymers, as long as the polymers are (i) miscible or compatible with each other and ( ii) the silane-functionalized polyolefin (or polyolefins) constitutes 70% by weight or 75% by weight or 80% by weight or 85% by weight or 90% by weight or 95% by weight or 98% by weight or 99% by weight to less than 100% by weight of the mixture.

[0080] The silane-functionalized polyolefin may comprise two or more embodiments disclosed in this document.

(B) LOAD

[0081] The crosslinkable composition includes a filler comprising more than 50% by weight of silica (silicon dioxide (SiO2)), based on the total weight of the filler.

[0082] The silica can be natural silica or synthetic silica. Synthetic silica includes fumed silica, electric arc silica, fused silica, silica gel and precipitated silica.

[0083] In one embodiment, the silica has an average particle size (D50) of 0.01 μm or 0.1 μm or 0.5 μm or 1.0 μm or 5.0 μm or 10.0 μm at 20 .0 μm or 25.0 μm or 30.0 μm, or 35.0 μm or 40.0 μm or 45.0 μm or 50.0 μm.

[0084] Silica can comprise two or more modalities disclosed here.

[0085] Silica may be the only filler or the filler may include one or more additional fillers. In one embodiment, the filler includes one or more additional or secondary fillers in combination with the silica. Non-limiting examples of suitable secondary fillers include aluminum oxide (alumina, Al2O3), titanium oxide (titania, TiO2), silicon carbide (SiC), glass particles, glass beads, plastic grains, quartz, coal fly ash. coal, calcium carbonate, barium sulfate, carbon black, metal oxides, inorganic material, natural material, alumina trihydrate, alumina silicate, magnesium hydroxide, bauxite, talc, mica, barite, kaolin, post glass consumer, post-industrial glass, synthetic and natural fiber or any combination thereof.

[0086] In another embodiment, the load includes from more than 50% by weight, or 60% by weight, or 70% by weight to 80% by weight, or 90% by weight, or 95% by weight, or 96 % by weight, or 97% by weight, or 98% by weight to 99% by weight, or 99.1% by weight, or 99.2% by weight, or 99.3% by weight or 99.4% by weight weight, or 99.5% by weight, or 99.6% by weight, or 99.7% by weight, or 99.8% by weight, or 99.9% by weight, or less than 100% by weight, or 100% by weight silica based on the total weight of the load.

[0087] In one embodiment, silica is the only filler. As the only filler, silica is the filler to the exclusion of all other fillers. In a further embodiment, silica is the only filler in the insulation or jacketing layer, to the exclusion of one, some or all of the following fillers: aluminum oxide (alumina, Al2O3), titanium oxide (titania, TiO2), carbon carbide silicon (SiC), glass particles, glass spheres, plastic grains, quartz, coal fly ash, calcium carbonate, barium sulfate, carbon black, metal oxides, inorganic material, natural material, alumina trihydrate, alumina silicate, magnesium hydroxide, bauxite, talc, mica, barite, kaolin, post-consumer glass, post-industrial glass and synthetic and natural fiber.

[0088] In one embodiment, silica is the only filler and the filler is metal-free. In one embodiment, the composition includes from 0% by weight, or more than 0% by weight, or 0.05% by weight, or 0.1% by weight to 0.15% by weight, or 0.2% by weight. weight, or 0.3% by weight, or 0.4% by weight, or 0.5% by weight of metals, based on the total weight of the load. As used herein, "metals" includes all elements listed as metals in the Periodic Table of Elements, including Li, Be, Na, Mg, Al, K, Ca, Sc, Ti, V, Cr, Mn, Fe, Co, Ni , Cu, Zn, Ga, Rb, Sr, Y, Zr, Nb, Mo, Tc, Ru, Rh, Pd, Ag, Cd, In, Sn, Cs, Ba, La, Hf, Ta, W, Re, Os , Ir, Pt, Au, Hg, Tl, Pb, Bi, Po, Fr, Ra, Ac, Rf, Db, Sg, Bh, Hs, Mt, Ds, Rg and Cn, as well as the lanthanides and actinides.

[0089] In one embodiment, the charge is a mixture of two or more charges, as described herein.

[0090] In one embodiment, the filler or a mixture of two or more fillers is present in an amount of 10% by weight, or 20% by weight, or 40% by weight, or 50% by weight, or 60% by weight. weight, or 70% by weight, or 80% by weight, or 90% by weight, based on the total weight of the crosslinkable composition.

[0091] The payload may comprise two or more embodiments disclosed herein.

(C) POLYMER CONTAINING SILICONE

[0092] The insulation or jacketing layer includes a silicone-containing polymer selected from silicone-containing linear reactive polymers, silicone-containing non-reactive linear polymers and/or silicone-containing non-reactive branched polymers. In one embodiment, the silicone-containing polymer is a reactive silicone-containing linear polymer or a non-reactive silicone-containing linear polymer.

[0093] The silicone-containing polymer has a density of 0.95 g/cm3, or 0.96 g/cm3, or 0.97 g/cm3 to 0.98 g/cm3, or 0.99 g/cm3, or 1.00 g/cm3 at 25 °C.

[0094] If a liquid at room temperature, the silicone-containing polymer has a kinematic viscosity of 0.01 cm2/s (1 cSt), or 0.5 cm2/s (50 cSt), or 1 cm2/s (100 cSt), or 5 cm% (500 cSt), or 10 cm% (1,000 cSt), or 50 cm2/s (5,000 cSt), or 100 cm2/s (10,000 cSt) to 150 cm2/s (15,000 cSt) or 250 cm2/s (25,000 cSt), or 500 cm2/s (50,000 cSt), or 750 cm2/s (75,000 cSt), or 10,000 cm2/s (1,000,000 cSt), or 50,000 cm2/s (5,000,000 cSt) at 25°C.

[0095] In one embodiment, the silicone-containing polymer is a reactive silicone-containing linear polymer or non-reactive silicone-containing linear polymer.

[0096] In one embodiment, the silicone-containing polymer is a polysiloxane. A polysiloxane is a polymer with the general structure (I): wherein R2 and R3 are each hydrogen or an alkyl group with the proviso that if the silicone-containing polymer is a linear polysiloxane, then both R2 and R3 must be H or a methyl group.

[0097] In one embodiment, the polysiloxane is a linear polysiloxane that has the general structure I, in which R2 and R3 are, independently, H or a methyl group. In one embodiment, the polysiloxane is a linear polysiloxane having the general structure I, wherein R2 and R3 are each a methyl group.

[0098] In one embodiment, the linear polysiloxane can be reactive or non-reactive. A reactive linear polysiloxane includes at least one terminal functional group, that is, a functional group at one end of the polymer. Non-limiting examples of suitable functional groups include groups that can undergo hydrolysis or condensation reactions, such as hydroxysiloxy groups or alkoxysiloxy groups. A nonreactive linear polysiloxane has terminal alkyl or aromatic groups.

[0099] Non-limiting examples of suitable linear polysiloxanes include linear polydimethylsiloxane (PDMS), linear poly(ethyl-methylsiloxane) and combinations thereof. A non-limiting example of a non-reactive linear polysiloxane is PMX-200, a polydimethylsiloxane polymer with terminal -Si(CH3)3 groups, available from Dow Corning. A non-limiting example of a reactive linear polysiloxane is XIAMETER® OHX-4000, a polydimethylsiloxane polymer with terminal silanol (e.g., -Si(CH3)2OH functionality), available from Dow Corning.

[00100] In one embodiment, the polysiloxane is a branched polysiloxane having the general structure (II) where x is 0 or 1, each R is independently and alkyl group or aryl group with one or more carbon atoms, A is the molar ratio of cross-linked units and is greater than 0, B is the molar ratio of linear units and is greater than 0 and A + B is equal to 1.00. In Structure II above, each "wedge bond" or " " indicates a bond to a Si in another polysiloxane chain.

[00101] In one embodiment, the A:B ratio is 1:99, or 5:95, or 25:75 to 95:5, or 97:3 or 99:1.

[00102] In one embodiment, the branched polysiloxane is a block polysiloxane having blocks of linear units and blocks of cross-linked units or a random polysiloxane having random equilibrium distributions of cross-linked units and linear units with a natural distribution of different structures.

[00103] Branched polysiloxane is a non-reactive branched polysiloxane.

[00104] In one embodiment, the silicone-containing polymer is a mixture of two or more silicone-containing polymers, as described herein. The mixture of two or more silicone-containing polymers is composed of 0% by weight or 5% by weight or 10% by weight or 20% by weight or 30% by weight or 40% by weight to 50% by weight or 60% by weight or 70% by weight or 75% by weight or 80% by weight or 85% by weight or 90% by weight or 95% by weight of a linear polysiloxane that is (i) reactive, (ii) non-reactive or ( iii) a mixture of reactive and non-reactive linear polysiloxanes and from 10% by weight or 15% by weight or 20% by weight or 25% by weight or 30% by weight or 40% by weight or 50% by weight to 60% by weight, or 70% by weight or 80% by weight or 90% by weight or 95% by weight or 100% by weight of a non-reactive branched polysiloxane.

[00105] In one embodiment, the silicone-containing polymer or mixture of silicone-containing polymers is present in an amount greater than 2% by weight or 3% by weight or 4% by weight or 4.25% by weight or 4, 5% by weight or 4.75% by weight to 5% by weight, or 5.5% by weight, or 6% by weight, or 7% by weight, or 8% by weight, or 9% by weight, or 10% by weight, or 15% by weight, or 20% by weight, based on the total weight of the crosslinkable composition.

[00106] The silicone-containing polymer may comprise two or more embodiments disclosed herein.

(D) SILANOL CONDENSATION CATALYST

[00107] In one embodiment, the composition includes silanol condensation catalyst, such as Lewis and Bronsted acids and bases. A "silanol condensation catalyst" promotes cross-linking of the silanol-functionalized polyolefin. Lewis acids are chemical species that can accept a pair of electrons from a Lewis base. Lewis bases are chemical species that can donate a pair of electrons to a Lewis acid. Non-limiting examples of suitable Lewis acids include tin carboxylates such as dibutyltin dilaurate (DBTDL), dimethylhydroxytin oleate, dioctyltin maleate, di-n-butyltin maleate, dibutyltin diacetate, dibutyltin dioctoate, stannous acetate , stannous octoate and several other organometallic compounds such as lead naphthenate, zinc caprylate and cobalt naphthenate. Non-limiting examples of suitable Lewis bases include primary, secondary and tertiary amines. These catalysts are typically used in moisture curing applications.

[00108] The silanol condensation catalyst is added to the crosslinkable composition during the cable manufacturing process. Therefore, silanol-functionalized polyolefin may experience some cross-linking before leaving the extruder with cross-linking completing after leaving the extruder upon exposure to moisture present in the environment in which it is stored, transported or used, although most cross-linking is delayed. until exposure of the final composition to moisture (e.g. a sauna bath or a cooling bath).

[00109] In one embodiment, the silanol condensation catalyst is included in a catalyst masterbatch mixture and the catalyst masterbatch is included in the composition. The catalyst master batch includes the silanol condensation catalyst on one or more carrier resins. In one embodiment, the carrier resin is the same as the polyolefin resin that is functionalized with silane to become the silane-functionalized polyolefin or other polymer that is non-reactive in the present composition. In one embodiment, the carrier resin is a mixture of two or more such resins. Non-limiting examples of suitable carrier resins include polyolefin homopolymers (e.g., polypropylene homopolymer, polyethylene homopolymer), propylene/alpha-olefin polymers, and ethylene/alpha-olefin polymers.

[00110] Non-limiting examples of suitable catalyst "master batch" include those sold under the trade name SI-LINK™ of The Dow Chemical Company, including SI-LINK™ DFDA-5481 Natural and SI-LINK™ AC DFDA-5488 NT. SI-LINK™ DFDA-5481 Natural is a master batch catalyst containing a blend of 1-butene/ethene polymer, ethene homopolymer, phenolic compound antioxidant, dibutyltin dilaurate (DBTDL) (a silanol condensation catalyst ) and a phenolic hydrazide compound. SI-LINK™ DFDA-5488 NT is a master batch catalyst that contains a mixture of a thermoplastic polymer, a phenolic compound antioxidant, and a hydrophobic acid catalyst (a silanol condensation catalyst).

[00111] In one embodiment, the silanol condensation catalyst is a mixture of two or more silanol condensation catalysts, as described herein.

[00112] In one embodiment, the silanol condensation catalyst or mixture of two or more silanol condensation catalysts is present in an amount of 0.002% by weight, or 0.005% by weight, or 0.01% by weight, or 0.02% by weight, or 0.05% by weight, or 0.08% by weight, or 0.1% by weight, or 0.15% by weight, or 0.2% by weight, or 0, 3% by weight, or 0.4% by weight, or 0.5% by weight, or 0.6% by weight, or 0.8% by weight, or 1.0% by weight to 1.5% by weight weight, or 2% by weight, or 4% by weight, or 5% by weight, or 6% by weight, or 8% by weight, or 10% by weight, or 15% by weight, or 20% by weight, based on the total weight of the crosslinkable composition.

[00113] In one embodiment, the composition contains from 0.5% by weight, or 1.0% by weight, or 2.0% by weight, or 3.0% by weight, or 4.0% by weight to 5.0% by weight, or 6.0% by weight, or 7.0% by weight, or 8.0% by weight, or 9.0% by weight, or 10.0% by weight, or 15.0 % by weight, or 20.0% by weight of catalyst masterbatch, based on the total weight of the crosslinkable composition.

[00114] The silanol condensation catalyst may comprise two or more embodiments disclosed in this document.

(E) OPTIONAL ADDITIVES

[00115] In one embodiment, the crosslinkable composition includes one or more optional additives. Non-limiting examples of suitable additives include metal deactivators, moisture scavengers, antioxidants, antiblocking agents, stabilizing agents, colorants, ultraviolet (UV) absorbers or stabilizers (e.g., mild hindered amine stabilizers (HALS) and titanium dioxide). , other flame retardants, compatibilizers, fillers and processing aids. Non-limiting examples of UV stabilizers include hindered.

[00116] Metal deactivators suppress the catalytic action of metal surfaces and traces of metallic minerals. Metal deactivators convert metal traces and metal surfaces into an inactive form, e.g. by sequestering. Non-limiting examples of suitable metal deactivators include 1,2-bis(3,5-di-tert-butyl-4-hydroxyhydrocinnamoyl)hydrazine, 2,2'-oxamindo bis[ethyl 3-(3,5-di -tert -butyl-4-hydroxyphenyl)propionate] and oxalyl bis(benzylidenehydrazide) (OABH). In one embodiment, the crosslinkable composition includes OABH. The metal deactivator is present in an amount from 0%, or more than 0% by weight, or 0.01% by weight, or 0.02% by weight, or 0.03% by weight, or 0 .04% by weight, or 0.05% by weight, or 0.1% by weight, or 0.5% by weight, or 1% by weight, or 2% by weight, or 3% by weight to 5% by weight, or 6% by weight, or 7% by weight, or 8% by weight, or 9% by weight, or 10% by weight, based on the total weight of the crosslinkable composition.

[00117] Moisture scavengers remove or deactivate unwanted water in the crosslinkable composition to prevent unwanted (premature) crosslinking and other reactions initiated by water in the crosslinkable composition. Non-limiting examples of moisture scavengers include organic compounds selected from ortho esters, acetals, ketals or silanes, such as alkoxy silanes. In one embodiment, the moisture scavenger is an alkoxysilane. The moisture scavenger is present in an amount of 0% by weight or greater than 0% by weight or 0.01% by weight or 0.02% by weight or 0.03% by weight or 0.04% by weight or 0.05% by weight or 0.1% by weight, or 0.2% by weight to 0.3% by weight or 0.5% by weight or 0.75% by weight or 1.0% by weight or 1.5% by weight or 2.0% by weight or 3.0% by weight, based on the total weight of the crosslinkable composition.

[00118] "Antioxidant" refers to types or classes of chemical compounds that can be used to minimize oxidation that may occur during polymer processing. Suitable antioxidants include high molecular weight hindered phenols and multifunctional phenols, such as phenol containing sulfur and phosphorus. Representative hindered phenols include 1,3,5-trimethyl-2,4,6-tris-(3,5-di-tert-butyl-4-hydroxybenzyl)-benzene; pentaerythrityl tetracys-3(3,5-di-tert-butyl-4-hydroxyphenyl)-propionate; n-octadecyl-3(3,5-di-tert-butyl-4-hydroxyphenyl)propionate; 4,4'-methylenebis(2,6-tert-butyl-phenol); 4,4'-thiobis(6-tert-butyl-o-cresol); 2,6-di-tert-butylphenol; 6-(4-hydroxyphenoxy)-2,4-bis(n-octyl-thio)-1,3,5-triazine; di-n-octylthio)ethyl 3,5-di-tert-butyl-4-hydroxybenzoate; and sorbitol hexa[3-(3,5-di-tert-butyl-4-hydroxy-phenyl)-propionate]. In one embodiment, the composition includes pentaerythritol tetracyl (3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate), commercially available as Irganox® 1010 from BASF. The antioxidant is present in an amount of 0% by weight, or greater than 0% by weight, 0.01% by weight, 0.02% by weight, or 0.03% by weight, or 0.04% by weight. weight, or 0.05% by weight, or 0.06% by weight, or 0.07% by weight, or 0.08% by weight, or 0.09% by weight, or 0.1% by weight to 0.12% by weight, or 0.14% by weight, or 0.16% by weight, or 0.18% by weight, or 0.2% by weight, or 0.25% by weight, or 0, 3% by weight, or 0.5% by weight, or 1% by weight, or 2% by weight, based on the total weight of the crosslinkable composition.

[00119] Other optional additives, including antiblocking agents, stabilizers, colorants, ultraviolet (UV) absorbers or stabilizers, other flame retardants, compatibilizers, fillers and processing aids, are present in an amount of 0% by weight or greater than 0% by weight or 0.01% by weight or 0.1% by weight to 1% by weight or 2% by weight or 3% by weight or 5% by weight or 10% by weight, based on the total weight of the composition.

RETICULABLE COMPOSITION

[00120] In one embodiment, the insulation or jacketing layer is a reaction product of a crosslinkable composition comprising (A) a silane-functionalized polyolefin, (B) a filler comprising more than 50% by weight silica, with based on the total weight of the filler, (C) a silicone-containing polymer and (D) 0.002% by weight to 20% by weight of a silanol* condensation catalyst, based on the total weight of the crosslinkable composition.

[00121] In one embodiment, the silane-functionalized polyolefin is present in an amount of 10% by weight, or 20% by weight, or 30% by weight, or 40% by weight, or 50% by weight to 60% by weight. weight, or 80% by weight, or 90% by weight, or 95% by weight, based on the total weight of the crosslinkable composition.

[00122] In one embodiment, the filler comprises more than 50% by weight silica, based on the total weight of the filler, and is present in an amount of 10% by weight or 20% by weight or 40% by weight to 50% by weight or 60% by weight, or 70% by weight, or 80% by weight, or 90% by weight, based on the total weight of the crosslinkable composition.

[00123] In one embodiment, the load comprises 50% by weight, or 60% by weight, or 70% by weight, or 80% by weight, or 90% by weight, or 95% by weight, or 96% by weight. weight, or 97% by weight, or 98% by weight to 99% by weight, or 99.1% by weight, or 99.2% by weight, or 99.3% by weight, or 99.4% by weight , or 99.5% by weight, or 99.6% by weight, or 99.7% by weight, or 99.8% by weight, or 99.9% by weight, or less than 100% by weight, or 100% by weight silica, based on the total weight of the load.

[00124] In one embodiment, the crosslinkable composition is free of filler, except the silica filler.

[00125] In one embodiment, the silicone-containing polymer is present in an amount greater than 2% by weight, or 3% by weight, or 4% by weight, or 4.25% by weight, or 4.5% by weight, or 4.75% by weight to 5% by weight, or 5.5% by weight or 6% by weight or 7% by weight or 8% by weight or 9% by weight or 10% by weight or 15 % by weight or 20% by weight, based on the total weight of the crosslinkable composition.

[00126] In one embodiment, the silanol condensation catalyst is present in an amount of 0.002% by weight, or 0.005% by weight, or 0.01% by weight, or 0.02% by weight, or 0.05 % by weight, or 0.08% by weight, or 0.1% by weight, or 0.15% by weight, or 0.2% by weight, or 0.3% by weight, or 0.4% by weight weight, or 0.5% by weight, or 0.6% by weight, or 0.8% by weight, or 1.0% by weight to 1.5% by weight, or 2% by weight, or 4% by weight, or 5% by weight, or 6% by weight, or 8% by weight, or 10% by weight, or 15% by weight, or 20% by weight, based on the total weight of the crosslinkable composition.

[00127] In one embodiment, a metal deactivator is present in an amount of 0% by weight, or greater than 0% by weight, or 0.01% by weight, or 0.02% by weight,, or 0. 03% by weight, or 0.04% by weight, or 0.05% by weight, or 0.1% by weight, or 0.5% by weight, or 1% by weight, or 2% by weight, or 3% by weight at 5 wt% or 6 wt% or 7 wt% or 8 wt% or 9 wt% or 10 wt%, based on the total weight of the crosslinkable composition.

[00128] In one embodiment, a moisture scavenger is present in an amount of 0% by weight, or greater than 0% by weight, or 0.01% by weight, or 0.02% by weight, or 0. 03% by weight, or 0.04% by weight, or 0.05% by weight, or 0.1% by weight, or 0.2% by weight to 0.3% by weight, or to 0.5% by weight, or 0.75% by weight, or 1.0% by weight, or 1.5% by weight, or 2.0% by weight, or 3.0% by weight, based in the total weight of the crosslinkable composition.

[00129] In one embodiment, an antioxidant is present in an amount of 0% by weight, or greater than 0% by weight, or 0.01% by weight, or 0.02% by weight, or 0.03% by weight, or 0.04% by weight, or 0.05% by weight, or 0.06% by weight, or 0.07% by weight, or 0.08% by weight, or 0.09% by weight , or 0.1% by weight to 0.12% by weight, or 0.14% by weight, or 0.16% by weight, or 0.18% by weight, or 0.2% by weight, or 0 .25% by weight, or 0.3% by weight, or 0.5% by weight, or 1% by weight, or 2% by weight, based on the total weight of the crosslinkable composition.

[00130] In one embodiment, one or more additives, for example, anti-blocking agents, stabilizing agents, colorants, UV absorbers or stabilizers, other flame retardants, compatibilizers, fillers and processing aids, are present in an amount of 0% by weight or more than 0% by weight, or 0.01% by weight, or 0.1% by weight to 1% by weight, or 2% by weight, or 3% by weight, or 5% by weight, or 10 % by weight, based on the total weight of the crosslinkable composition.

[00131] In one embodiment, the crosslinkable composition is metal free. The metal-free crosslinkable composition contains from 0% by weight, or more than 0% by weight, or 0.05% by weight, or 0.1% by weight to 0.15% by weight, or 0.2% by weight, or 0.3% by weight, or 0.4% by weight, or 0.5% by weight of metals, based on the total weight of the crosslinkable composition. As used herein, "metals" includes all elements listed as metals in the Periodic Table of Elements, including Li, Be, Na, Mg, Al, K, Ca, Sc, Ti, V, Cr, Mn, Fe, Co , Ni, Cu, Zn, Ga, Rb, Sr, Y, Zr, Nb, Mo, Tc, Ru, Rh, Pd, Ag, Cd, Ag, Cd, In, Sn, Cs, Ba, La, Hf, Ta , W, Re, Os, Ir, Pt, Au, Hg, Tl, Pb, Bi, Po, Fr, Ra, Ac, Rf, Db, Sg, Bh, Hs, Mt, Ds, Rg and Cn, as well as the lanthanides and actinides.

[00132] The crosslinkable composition can be prepared by dry mixing or by melt mixing the individual components and additives. The molten mixture can be pelletized for future use or immediately transferred to an extruder to form an insulation layer or jacket and/or coated conductor. For convenience, certain ingredients may be premixed, such as through melt processing or in master batches.

[00133] In one embodiment, the crosslinkable composition is moisture curable.

[00134] The crosslinkable composition may comprise two or more embodiments disclosed in this document.

INSULATION OR JACKING LAYER

[00135] In one embodiment, the crosslinkable composition is used to form a shirt layer. In one embodiment, the jacket layer is an insulation layer.

[00136] The process for producing an insulation or jacketing layer includes heating the crosslinkable composition to at least the melting temperature of the silane-functionalized polyolefin and then extruding the molten polymer mixture into a conductor. The term “in” includes direct contact or indirect contact between the molten mixture and the conductor. The molten mixture is in an extrudable state.

[00137] The insulation or jacketing layer is crosslinked. In one embodiment, cross-linking begins in the extruder, but only to a minimal extent. In another embodiment, cross-linking is delayed until the composition is cured by exposure to moisture ("moisture curing").

[00138] As used herein, "moisture curing" is the hydrolysis of hydrolyzable groups by exposing silane-functionalized polyolefin to water, producing silanol groups that then undergo condensation (with the aid of the silanol condensation catalyst) to form silane bonds. Silane bonds couple or cross-link polymer chains to produce silane-coupled polyolefin. A schematic representation of the moisture curing reaction is given in reaction (V) below.

[00139] In one embodiment, the moisture is water. In one embodiment, moisture curing is conducted by exposing the insulation or jacketing layer or coated conductor to water in the form of moisture (e.g., water gas or vapor) or by submerging the insulation or jacketing layer or conductor coated in a water bath. Relative humidity can reach 100%.

[00140] In one embodiment, moisture curing occurs at a temperature from room temperature (ambient conditions) to 100 °C for a duration of 1 hour or 4 hours or 12 hours or 24 hours or 3 days or 5 days at 6 days or 8 days or 10 days or 12 days or 14 days or 28 days or 60 days.

[00141] In one embodiment, the disclosure provides an insulation or jacketing layer for a coated conductor comprising (A) a cross-linked silane functionalized polyolefin, (B) a filler comprising more than 50% by weight silica, based in the total weight of the charge, (C) a silicone-containing polymer and (D) from 0.00% by weight to 20% by weight of a silanol condensation catalyst based on the total weight of the insulation or jacketing layer.

[00142] In one embodiment, the silane-functionalized polyolefin is present in an amount of 10% by weight, or 20% by weight, or 30%, or 40% by weight, or 50% by weight to 60% by weight, or 80% by weight, or 90% by weight, or 95%, based on the total weight of the insulation or jacketing layer.

[00143] In one embodiment, the filler comprises more than 50% by weight silica, based on the total weight of the filler, and is present in an amount of 10% by weight, or 20% by weight, or 40% by weight to 50% by weight, or 60% by weight or 70% by weight or 80% by weight or 90% by weight, based on the total weight of the insulation layer or jacket.

[00144] In one embodiment, the load comprises 50% by weight, or 60% by weight, or 70% by weight, or 80% by weight, or 90% by weight, or 95% by weight, or 96% by weight. weight, or 97% by weight, or 98% by weight to 99% by weight, or 99.1% by weight, or 99.2% and weight, or 99.3% by weight, or 99.4% by weight , or 99.5% by weight, or 99.6% by weight, or 99.7% by weight, or 99.8% by weight, or 99.9% by weight, or less than 100% by weight, or 100% by weight silica, based on the total weight of the load.

[00145] In one embodiment, the insulation or jacketing layer contains silica as the only filler. Silica is the only filler to the exclusion of other fillers.

[00146] In one embodiment, the silicone-containing polymer is present in an amount greater than 2% by weight, or 3% by weight, or 4% by weight, or 4.25% by weight, or 4.5% by weight. weight, or 4.75% by weight to 5% by weight, or 5.5% by weight or 6% by weight or 7% by weight or 8% by weight or 9% by weight or 10% by weight or 15% by weight or 20% by weight, based on the total weight of the insulation or jacketing layer.

[00147] In one embodiment, the silanol condensation catalyst is present in an amount of 0.00% by weight, or 0.001% by weight, or 0.002% by weight, or 0.005% by weight, or 0.01% by weight. weight, or 0.02% by weight, or 0.05% by weight, or 0.08% by weight, or 0.1% by weight, or 0.15% by weight, or 0.2% by weight, or 0.3% by weight, or 0.4% by weight, or 0.5% by weight, or 0.6% by weight, or 0.8% by weight, or 1.0% by weight to 1, 5% by weight, or 2% by weight, or 4% by weight, or 5% by weight, or 6% by weight, or 8% by weight, or 10% by weight, or 15% by weight, or 20% by weight, based on the total weight of the insulation layer or jacket.

[00148] In one embodiment, a metal deactivator is present in an amount of 0% by weight, or greater than 0% by weight, or 0.01% by weight, or 0.02% by weight,, or 0. 03% by weight, or 0.04% by weight, or 0.05% by weight, or 0.1% by weight, or 0.5% by weight, or 1% by weight, or 2% by weight, or 3% by weight to 5% by weight or 6% by weight or 7% by weight or 8% by weight or 9% by weight or 10% by weight %, based on the total weight of the insulation layer or jacket.

[00149] In one embodiment, a moisture scavenger is present in an amount of 0% by weight, or greater than 0% by weight, or 0.01% by weight, or 0.02% by weight,, or 0. 03% by weight, or 0.04% by weight, or 0.05% by weight, or 0.1% by weight, or 0.2% by weight to 0.3% by weight, or 0.5% by weight weight, or 0.75% by weight, or 1.0% by weight, or 1.5% by weight, or 2.0% by weight, or 3.0% by weight, based on the total weight of the layer insulation or jacketing.

[00150] In one embodiment, an antioxidant is present in an amount of 0% by weight, or greater than 0% by weight, or 0.01% by weight, or 0.02% by weight, or 0.03% by weight, or 0.04% by weight, or 0.05% by weight, or 0.06% by weight, or 0.07% by weight, or 0.08% by weight, or 0.09% by weight , or 0.1% by weight to 0.12% by weight, or 0.14% by weight, or 0.16% by weight, or 0.18% by weight, or 0.2% by weight, or 0 .25% by weight, or 0.3% by weight, or 0.5% by weight, or 1% by weight, or 2% by weight, based on the total weight of the insulation layer or jacket.

[00151] In one embodiment, one or more additives, for example, anti-blocking agents, stabilizing agents, colorants, UV absorbers or stabilizers, other flame retardants, compatibilizers, fillers and processing aids, are present in an amount of 0% by weight or more than 0% by weight or 0.01% by weight or 0.1% by weight to 1% by weight or 2% by weight or 3% by weight or 5% by weight or 10% by weight, with based on the total weight of the insulation or jacketing layer.

[00152] In one embodiment, the insulation or jacketing layer includes silica with the sole charge (silica being present to the exclusion of all other fillers) and the insulation or jacketing layer is free of metals. The metal-free insulation or jacketing layer contains from 0% by weight or more than 0% by weight or 0.05% by weight or 0.1% by weight to 0.15% by weight or 0.2% by weight or 0.3% by weight or 0.4% by weight, or 0.5% by weight of metals, based on the total weight of the insulation or jacketing layer. As used herein, "metals" includes all elements listed as metals in the Periodic Table of Elements, including Li, Be, Na, Mg, Al, K, Ca, Sc, Ti, V, Cr, Mn, Fe, Co , Ni, Cu, Zn, Ga, Rb, Sr, Y, Zr, Nb, Mo, Tc, Ru, Rh, Pd, Ag, Cd, Ag, Cd, In, Sn, Cs, Ba, La, Hf, Ta , W, Re, Os, Ir, Pt, Au, Hg, Tl, Pb, Bi, Po, Fr, Ra, Ac, Rf, Db, Sg, Bh, Hs, Mt, Ds, Rg and Cn, as well as the lanthanides and actinides.

[00153] In one embodiment, the insulation or jacketing layer has a thickness of 0.127 mm (5 mil) or 0.254 mm (10 mil) or 0.381 mm (15 mil) or 0.508 mm (20 mil) to 0.635 mm (25 mil). ) or 0.762 mm (30 mil) or 0.889 mm (35 mil) or 1 mm (40 mil) or 1.27 mm (50 mil) or 1.9 mm (75 mil) or 2.54 mm (100 mil).

[00154] In one embodiment, the insulation or jacketing layer passes the horizontal burn test as defined in Horizontal Flame UL 2556. To pass the horizontal burn test, the insulation or jacketing layer must have a total value of less than 100mm. In one embodiment, the insulation or jacketing layer has a total value during the horizontal burn test of 20 mm or 25 mm or 30 mm to 50 mm or 55 mm or 60 mm or 70 mm or 75 mm or 80 mm or 90 mm or less than 100 mm.

[00155] In one embodiment, the insulation layer or jacket has a wet insulation resistance ratio of 1.10, or 1.15, or 1.20, or 1.25 to 1.30, or 1.35, or 1.40, or 1.45, or 1.50, or 1.55, or 1.60, or 1.70.

[00156] In one embodiment, the insulation layer or jacket has a wet insulation resistance ratio of 1.10, or 1.15, or 1.20, or 1.25 to 1.30, or 1.35, or 1.40, or 1.45, or 1.50, or 1.55, or 1.60, or 1.70 and passes the horizontal burn test.

[00157] INSULATION LAYER OR JACKET 1: in one embodiment, the insulation layer or jacket comprises: (a) from 40% by weight, or 45% by weight, or 47% by weight, or 50% by weight to 52 % by weight, or 55% by weight, or 60% by weight, based on the total weight of the insulation layer or jacket, of a silane-grafted polyethylene; (B) from 40% by weight, or 42% by weight, or 45% by weight to 50% by weight, or 52% by weight, or 55% by weight, or 60% by weight, based on the total weight of the insulation layer or jacket, filler comprising more than 50% by weight silica, based on the total weight of the load; (C) from 4.75% by weight, or 4.8% by weight, or 4.9% by weight, or 5% by weight to 5.1% by weight, or 5.2% by weight, or 5 .3% by weight, based on the total weight of the insulation layer or jacket, of a silicone-containing polymer; and (D) 0.00% by weight, or 0.001% by weight, or 0.002% by weight, or 0.005% by weight, or 0.01% by weight, or 0.02% by weight, or 0.05 % by weight, or 0.08% by weight, or 0.1% by weight, or 0.15% by weight, or 0.2% by weight, or 0.3% by weight, or 0.4% by weight weight, or 0.5% by weight, or 0.6% by weight, or 0.8% by weight, or 1.0% by weight to 1.5% by weight, or 2% by weight, or 4% by weight, or 5% by weight, or 6% by weight, or 8% by weight, or 10% by weight, based on the total weight of the insulation layer or jacket, of a silanol condensation catalyst.

[00158] INSULATION LAYER OR JACKET 2: in one embodiment, the insulation layer or jacket comprises (a) 40% by weight, or 45% by weight, or 47% by weight, or 50% by weight to 52% by weight, or 55% by weight or 60% by weight, based on the total weight of the insulation layer or jacket, of a silane-grafted polyethylene; (B) from 40% by weight, or 42% by weight, or 45% by weight to 50% by weight, or 52% by weight, or 55% by weight, or 60% by weight, based on the total weight of the layer insulation or jacket, silica filler, wherein the silica filler is the sole filler to the exclusion of other fillers; and (C) from 4.75% by weight, or 4.8% by weight, or 4.9% by weight, or 5% by weight to 5.1% by weight, or 5.2% by weight, or 5 .3% by weight, based on the total weight of the insulation layer or jacket, of a silicone-containing polymer; and 0.00% by weight, or 0.001% by weight, or 0.002% by weight, or 0.005% by weight, or 0.01% by weight, or 0.02% by weight, or 0.05% by weight , or 0.08% by weight, or 0.1% by weight, or 0.15% by weight, or 0.2% by weight, or 0.3% by weight, or 0.4% by weight, or 0.5 wt%, or 0.6 wt%, or 0.8 wt%, or 1.0 wt% to 1.5 wt%, or 2 wt%, or 4 wt%, or 5% by weight, or 6% by weight, or 8% by weight or 10% by weight, based on the total weight of the insulation layer or jacket, of a silanol condensation catalyst.

[00159] In one embodiment, the insulation layer is according to INSULATION LAYER OR SHIRT 1 or INSULATION LAYER OR SHIRT 2 with one, some or all of the following properties: (i) it is metal-free; and/or (ii) a wet insulation resistance ratio greater than or equal to 1.10 ohms, or 1.15 ohms, or 1.20 ohms, or 1.25 ohms to 1.30 ohms, or 1.35 ohms , or 1.40 ohms, or 1.45 ohms, or 1.50 ohms or 1.55 ohms; and/or (iii) passes the horizontal burn test.

[00160] In one embodiment, the insulation layer or jacket has at least 2 or all 3 properties (i) to (iii).

[00161] In one embodiment, the insulation layer or jacket is according to INSULATION LAYER OR JACKET 1 or INSULATION LAYER OR JACKET 2, wherein the silicone-containing polymer is a reactive linear polysiloxane and wherein the silicone layer is insulation or coating has one, some or all of the following properties: (i) it is metal-free; and/or (ii) a wet insulation resistance ratio greater than or equal to 1.10, or 1.15, or 1.20, or 1.25 to 1.30, or 1.35, or 1.40, or 1.45, or 1.50 or 1.55; and/or (iii) passes the horizontal burn test.

[00162] In one embodiment, the insulation layer or jacket has at least 2 or all 3 properties (i) to (iii).

[00163] In one embodiment, the insulation layer or jacket is according to INSULATION LAYER OR JACKET 1 or INSULATION LAYER OR JACKET 2, wherein the silicone-containing polymer is a non-reactive linear polysiloxane and wherein the layer insulation or jacket has one, some, or all of the following properties: (i) is metal-free; and/or (ii) a wet insulation resistance ratio greater than or equal to 1.10, or 1.15, or 1.20, or 1.25 to 1.30, or 1.35, or 1.40, or 1.45, or 1.50 or 1.55; and/or (iii) passes the horizontal burn test.

[00164] In one embodiment, the insulation layer or jacket has at least 2 or all 3 properties (i) to (iii).

[00165] In one embodiment, the insulation layer or jacket is according to INSULATION LAYER OR JACKET 1 or INSULATION LAYER OR JACKET 2, wherein the silicone-containing polymer is a non-reactive branched polysiloxane and wherein the layer of insulation or coating has one, some, or all of the following properties: (i) is metal-free; and/or (ii) a wet insulation resistance ratio greater than or equal to 1.10, or 1.15, or 1.20, or 1.25 to 1.30, or 1.35, or 1.40, or 1.45, or 1.50 or 1.55; and/or (iii) passes the horizontal burn test.

[00166] In one embodiment, the insulation layer or jacket has at least 2 or all 3 properties (i) to (iii).

[00167] Although silica does not decompose at elevated temperatures to release gas, it was surprisingly discovered that the insulation layer or jacket passes the horizontal burning test. Not to be bound by any particular theory, silica and silicone-containing polymer are believed to exhibit an unexpected synergy. The silicone-containing polymer decomposes at high temperatures, forming an inorganic carbon that binds the silica particles. Furthermore, it was surprisingly found that the insulation layer or jacket improved the wet insulation resistance. Not to be limited by any particular theory, it is believed that the surface of the silica particles interacts with the silane-functionalized polyolefin, resulting in a better distribution of the silica particles being more discrete and more dispersed in the silane-functionalized polyolefin matrix. . When silica particles are in contact with each other, there is the potential for water to rupture the silica interface. However, when the particles are not in contact, it is more difficult for water to penetrate the interface.

[00168] The insulation layer or jacket may comprise two or more embodiments disclosed herein.

COATED CONDUCTOR

[00169] In one embodiment, the disclosure provides a coated conductor comprising a coating on the conductor, the coating comprising (A) a cross-linked silane-functionalized polyolefin, (B) a filler comprising more than 50% by weight silica, with based on the total weight of the filler, (C) a silicone-containing polymer and (D) from 0.00% by weight to 20% by weight, based on the total weight of the coating, of a silanol condensation catalyst.

[00170] The process for producing a coated conductor includes heating the present composition to at least the melting temperature of the silanol-functionalized polyolefin and then extruding the molten mixture into the conductor. The term “in” includes direct contact or indirect contact between the molten mixture and the conductor. The molten mixture is in an extrudable state.

[00171] The coating is crosslinked. In one embodiment, cross-linking begins in the extruder, but only to a minimal extent. In another embodiment, cross-linking is delayed until the composition is cured by exposure to moisture ("moisture curing").

[00172] In one embodiment, the moisture is water. In one embodiment, moisture curing is conducted by exposing the coated conductor to water in the form of moisture (e.g., water in a gaseous state) or by submerging the insulation layer or jacket or the coated conductor in a water bath. Relative humidity can reach 100%.

[00173] In one embodiment, moisture curing occurs at a temperature from room temperature (ambient conditions) to 100 ° C for a duration of 1 hour, or 4 hours, or 12 hours, or 24 hours, or 2 days, or 3 days, or 5 days to 6 days, 8 days, or 10 days, or 12 days, or 14 days, or 28 days or 60 days.

[00174] In one embodiment, the silane-functionalized polyolefin is present in an amount of 10% by weight, or 20% by weight, or 30% by weight, or 40% by weight, or 50% by weight to 60% by weight. weight, or 80% by weight, or 90% by weight, or 95% by weight, based on the total weight of the coating.

[00175] In one embodiment, the filler comprises more than 50% by weight silica, based on the total weight of the filler, and is present in an amount of 10% by weight, or 20% by weight, or 40% by weight at 50% by weight, or 60% by weight, or 70% by weight, or 80% by weight, or 90% by weight, based on the total weight of the crosslinkable composition.

[00176] In one embodiment, the load comprises 50% by weight, or 60% by weight, or 70% by weight, or 80% by weight, or 90% by weight, or 95% by weight, or 96% by weight. weight, or 97% by weight, or 98% by weight to 99% by weight, or 99.1% by weight, or 99.2% by weight, or 99.3% by weight, or 99.4% by weight , or 99.5% by weight, or 99.6% by weight, or 99.7% by weight, or 99.8% by weight, or 99.9% by weight, or less than 100% by weight, or 100% by weight silica, based on the total weight of the load.

[00177] In one embodiment, the coating contains silica as the only filler. Silica is the only filler to the exclusion of other fillers.

[00178] In one embodiment, the silicone-containing polymer is present in an amount greater than 2% by weight, or 3% by weight, or 4% by weight, or 4.25% by weight, or 4.5% by weight. weight, or 4.75% by weight to 5% by weight, or 5.5% by weight, or 6% by weight, or 7% by weight, or 8% by weight, or 9% by weight, or 10% by weight, or 15% by weight or 20% by weight based on the total weight of the coating.

[00179] In one embodiment, the antioxidant is present in an amount of 0.00% by weight, or 0.001% by weight, or 0.002% by weight, 0.005% by weight, or 0.01% by weight, or 0. 02% by weight, or 0.05% by weight, or 0.08% by weight, or 0.1% by weight, or 0.15% by weight, or 0.2% by weight, or 0.3% by weight, or 0.4% by weight, or 0.5% by weight, or 0.6% by weight to 0.8% by weight, 1.0% by weight, or 1.5% by weight, or 2% by weight, or 4% by weight, or 5% by weight, or 6% by weight, or 8% by weight, or 10% by weight, or 15% by weight, or 20% by weight, based on the total weight of the cargo composition.

[00180] In one embodiment, a metal deactivator is present in an amount of 0% by weight, or greater than 0% by weight, or 0.01% by weight, or 0.02% by weight to 0.03% by weight, or 0.04% by weight, or 0.05% by weight, or 0.1% by weight, or 0.5% by weight, or 1% by weight, or 2% by weight, or 3% by weight to 5% by weight, or 6% by weight, or 7% by weight, or 8% by weight, or 9% by weight, or 10% by weight, based on the total weight of the coating.

[00181] In one embodiment, the moisture scavenger is present in an amount of 0% by weight, or greater than 0% by weight, or 0.01% by weight, or 0.02% by weight, or 0.03 % by weight, or 0.04% by weight, or 0.05% by weight, or 0.1% by weight, or 0.2% by weight to 0.3% by weight, or to 0.5% by weight weight, or at 0.75% by weight, or at 1.0% by weight, or at 1.5% by weight, or at 2.0% by weight, or at 3.0% based on the total weight of the coating.

[00182] In one embodiment, the antioxidant is present in an amount of 0% by weight, or greater than 0% by weight, 0.01% by weight, 0.02% by weight, or 0.03% by weight, or 0.04% by weight, or 0.05% by weight, or 0.06% by weight, or 0.07% by weight, or 0.08% by weight, or 0.09% by weight, or 0 .1% by weight to 0.12% by weight, or 0.14% by weight, or 0.16% by weight, or 0.18% by weight, or 0.2% by weight, or 0.25% by weight, or 0.3% by weight, or 0.5% by weight, or 1.0% by weight, or 2.0% by weight, based on the total weight of the filler composition.

[00183] In one embodiment, one or more additives, for example, anti-blocking agents, stabilizing agents, colorants, UV absorbers or stabilizers, flame retardants, compatibilizers, fillers and processing aids, are present in an amount of 0% in weight, or greater than 0% by weight, or 0.01% by weight, or 0.1% by weight, or 1% by weight, or 2% by weight, or 3% by weight, based on the total weight of the coating .

[00184] In one embodiment, the coating is metal-free. In one embodiment, the term "metal-free" means containing from 0% by weight, or greater than 0% by weight, or 0.05% by weight, or 0.1% by weight to 0.15% by weight, or 0.2% by weight, or 0.3% by weight, or 0.4% by weight, or 0.5% by weight of metals, based on the total weight of the coating. As used herein, "metals" includes all elements listed as metals in the Periodic Table of Elements, including Li, Be, Na, Mg, Al, K, Ca, Sc, Ti, V, Cr, Mn, Fe, Co, Ni , Cu, Zn, Ga, Rb, Sr, Y, Zr, Nb, Mo, Tc, Ru, Rh, Pd, Ag, Cd, In, Sn, Cs, Ba, La, Hf, Ta, W, Re, Os , Ir, Pt, Au, Hg, Tl, Pb, Bi, Po, Fr, Ra, Ac, Rf, Db, Sg, Bh, Hs, Mt, Ds, Rg and Cn, as well as the lanthanides and actinides.

[00185] The coating may be one or more internal layers. The covering may fully or partially cover or otherwise surround or enclose the conductor. The jacket may be the only component surrounding the conductor. Alternatively, the coating may be a layer of a multilayer coating or sheath that encloses the conductor. In one embodiment, the coating comes into direct contact with the conductor. In another embodiment, the coating directly contacts an intermediate layer surrounding the conductor.

[00186] In one embodiment, the coating has a thickness of 0.127 mm (5 mil) or 0.254 mm (10 mil) or 0.381 mm (15 mil) or 0.508 mm (20 mil) to 0.635 mm (25 mil) or 0.762 mm (30 mil) or 0.889 mm (35 mil) or 1 mm (40 mil) or 1.27 mm (50 mil) or 1.9 mm (75 mil) or 2.54 mm (100 mil).

[00187] In one embodiment, the coated conductor has a wet insulation resistance ratio greater than or equal to 1.00 or greater than 1.10 or greater than 1.20.

[00188] In one embodiment, the sheathed conductor has a wet insulation resistance ratio greater than or equal to 1.00, or 1.05, or 1.10, or 1.15, or 1.20, or 1.25 to 1 .30, or 1.35, or 1.40, or 1.45, or 1.50, or 1.55 or 1.60 or 1.70.

[00189] In one embodiment, the coated conductor passes the horizontal burn test. To pass the horizontal burn test, the coating must have a total value of less than 100 mm. In one embodiment, the sheathed conductor has a total charge during the horizontal burn test of 0 mm, or 5 mm, or 10 mm to 50 mm, or 55 mm, or 60 mm, or 70 mm, or 75 mm, or 80 mm, or 90 mm or less than 100 mm.

[00190] In one embodiment, the coating on the coated conductor is in accordance with INSULATION LAYER OR SHACKING 1 or INSULATION LAYER OR SHACKING 2, wherein the coated conductor has one, some or all of the following properties: (i) the coating is metal free; and/or (ii) a wet insulation resistance ratio greater than or equal to 1.10, or 1.15, or 1.20, or 1.25 to 1.30, or 1.35, or 1.40, or 1.45, or 1.50 or 1.55; and/or (iii) the coated conductor passes the horizontal burn test.

[00191] In one embodiment, the coated conductor has at least 2 or all 3 properties (i) to (iii).

[00192] In one embodiment, the coating on the coated conductor is in accordance with INSULATION LAYER OR SHACKING 1 or INSULATION LAYER OR SHACKING 2, wherein the silicone-containing polymer is a reactive linear polysiloxane and the coated conductor has a, some or all of the following properties: (i) the coating is metal free; and/or (ii) a wet insulation resistance ratio greater than or equal to 1.10, or 1.15, or 1.20, or 1.25 to 1.30, or 1.35, or 1.40, or 1.45, or 1.50 or 1.55; and/or (iii) the coated conductor passes the horizontal burn test.

[00193] In one embodiment, the coated conductor has at least 2 or all 3 properties (i) to (iii).

[00194] In one embodiment, the coating on the coated conductor is in accordance with INSULATION LAYER OR SHACKING 1 or INSULATION LAYER OR SHACKING 2, wherein the silicone-containing polymer is a non-reactive linear polysiloxane and the coated conductor has a , some or all of the following properties: (i) the coating is metal free; and/or (ii) a wet insulation resistance ratio greater than or equal to 1.10, or 1.15, or 1.20, or 1.25 to 1.30, or 1.35, or 1.40, or 1.45, or 1.50 or 1.55; and/or (iii) the coated conductor passes the horizontal burn test.

[00195] In one embodiment, the coated conductor has at least 2 or all 3 properties (i) to (iii).

[00196] In one embodiment, the coating on the coated conductor is in accordance with INSULATION LAYER OR SHACKING 1 or INSULATION LAYER OR SHACKING 2, wherein the silicone-containing polymer is a non-reactive branched polysiloxane and the coated conductor has a , some or all of the following properties: (i) the coating is metal free; and/or (ii) a wet insulation resistance ratio greater than or equal to 1.10, or 1.15, or 1.20, or 1.25 to 1.30, or 1.35, or 1.40, or 1.45, or 1.50 or 1.55; and/or (iii) the coated conductor passes the horizontal burn test.

[00197] In one embodiment, the coated conductor has at least 2 or all 3 properties (i) to (iii).

[00198] In one embodiment, the coating is a shirt layer. In one embodiment, the jacket layer is an insulation layer.

[00199] The coated conductor may comprise two or more embodiments disclosed herein.

[00200] Some embodiments of the invention will now be described in detail in the following Examples.

EXAMPLES MATERIALS

[00201] ENGAGE 8402 is an ethylene-octene copolymer with a density of 0.902 g/cm3 and an MI of 30 g/10 min.

[00202] OVTMS is a vinyl trimethoxysilane with a density of 0.968 g/ml at 25 °C and a boiling point of 123 °C.

[00203] Luperox 101 is a 2,5-bis(tert-butylperoxy)-2,5-dimethylhexane graft initiator.

[00204] Filler 1 is Min-U-Sil 5, a crystalline silica filler with a D90 of 5 microns and a purity of 99.4%.

[00205] Charge 2 is Huber Zerogen 100SV, a magnesium hydroxide surface treated charge with an average particle size of 0.8 μm.

[00206] Filler 3 is Kisuma 5J, a magnesium hydroxide surface treated filler with an average particle size of 0.8 to 1.2 μm.

[00207] Filler 4 is Huber Q1, a calcium carbonate filler with no surface treatment and an average particle size of 1.1 μm.

[00208] Charge 5 is Huber Q1T, a calcium carbonate surface-treated charge with an average particle size of 1.1 μm.

[00209] Filler 6 is OMYACARB® 10, a calcium carbonate without surface treatment and an average particle size of 12 μm.

[00210] AO is Irganox 1010 (antioxidant).

[00211] Silicone-containing Polymer 1 (SCP1) is XIAMETER® PMX-200 (1M cSt), a non-reactive linear polydimethylsiloxane (dimethylsiloxane, terminated with trimethylsiloxy) with a specific gravity of 0.978 at 25 °C and a kinematic viscosity of 10,000 cm2/s (1,000,000 Centistokes).

[00212] SCP2 is XIAMETER® PMX-200 (60k cSt), a non-reactive linear polydimethylsiloxane (dimethyl siloxane, terminated with trimethylsiloxy) with a specific gravity of 0.978 at 25 °C and a kinematic viscosity of 600 cm2/s ( 60,000 Centistokes).

[00213] SCP3 is XIAMETER (R) OHX-4000, a reactive linear polydimethylsiloxane with terminal silanol groups (hydroxy-terminated dimethylsiloxane) with a density of 0.972 g/cm3 and a dynamic viscosity of 2,000 mPa.s.

[00214] The metal deactivator (MD) is oxalyl bis (benzylidene) hydroxide.

[00215] The moisture scavenger (MS) is hexadecyltrimethoxysilane.

[00216] ENGAGE 8450 is an ethylene/octene copolymer that has a density of 0.902 g/cm3 and an MI of 3.0 g/10 min.

[00217] DFH-2065 is a linear low-density polyethylene, with a melt index of 0.65 grams/10 minutes and a density of 0.920 g/cm3, available from The Dow Chemical Company

[00218] DFDA-1216 NT LDPE is a low-density polyethylene with a density of 0.92 g/cm3 and a melt index of 2.3 g/10 min and is available from The Dow Chemical Company.

[00219] Dibutyltin dilaurate is the silanol condensation catalyst.

[00220] 1,2-bis(3,5-di-tert-butyl-4-hydroxyhydrocinnamoyl)hydrazine is an antioxidant.

[00221] Tetrakis (methylene (3,5-di-tert-butyl-4-hydroxyhydrocinnamate)) methane is a stabilizer.

SAMPLE PREPARATION

[00222] A silane-grafted polyethylene is prepared by reactive extrusion through a twin-screw extruder. 1.8% by weight, based on the total weight of the base resin (ENGAGE 8402), of vinyl trimethoxysilane (VTMS) and 900 ppm based on the total weight of the base resin (ENGAGE 8402) of Luperox 101 are weighed and mixed, followed by approximately 10 to 15 minutes of magnetic stirring to obtain a uniform liquid mixture. The mixture is placed on a scale and connected to a liquid pump injection. The ENGAGE 8402 is fed into the main feeder of the ZSK-30 extruder. The barrel temperature profile of the ZSK-30 is defined as follows: 2 to 3 160 °C 6 to 7 225 °C 10 to 11 170 °C 4 to 5 195 °C 8 to 9 225 °C with the temperature of bead water as close to 10°C (50°F) as possible and chiller water temperature as close to 4°C (40°C) as possible.

[00223] The amount of VTMS grafted onto polyethylene is determined by infrared spectroscopy. Spectra are measured with a Nicolet 6700 FTIR instrument. The absolute value is measured by FTIR mode without interference from surface contamination. The ratio of the absorbances at 1192 cm-1 and 2019 cm-1 (internal thicknesses) is determined. The height ratio of the 1192/2019 peak heights is compared to standards with known VTMS levels in DFDA-5451 (available as SI-LINK 5451 from the Dow Chemical Company). The results show that the grafted VTMS content of silane-grafted polyethylene (Si-g-PE) is about 1.7% by mass, based on the total mass of the polymer.

[00224] Si-g-PE is added to a Brabender at about 140°C and the silica filler, silicone-containing polymer, metal deactivator, moisture scavenger and the antioxidant Irganox 1010 are added to the bowl after the Si -g-PE be melted in the amounts specified in Tables 1 and 3 below. The mixture is mixed for about 5 minutes.

[00225] The mixture is then pelletized into small pieces for wire extrusion. In the extrusion step, the silanol condensation catalyst, in the form of a master batch, as shown in Table 2, below, is added with the pelletized mixture to extrude the wire into the 0.064 diameter copper wire. The wall thickness is set at around 30mil and the extrusion temperature is 140°C to a temperature of 165°C. The concentration of silanol condensation catalyst in the overall composition is in the range of 0.01 wt% to 0.5 wt%.

[00226] The extruded wires are cured in a water bath at 90 °C overnight and the cured wires are cut into 15 foot (4.572 meter) long segments. The wet RI of the 10-foot (3.048 meter) long segments immersed in water is recorded and the wet RI rate is recorded, if applicable.

[00227] The horizontal burn test is applied to extruded wires in accordance with UL-2556. A burner is set at an angle of 20° to the horizontal of the sample (14 AWG copper wire with 30 mil wall thickness). A single flame is applied to the middle of the sample for 30 seconds. The sample fails when the cotton ignites (reported in seconds) or the samples are greater than 100 mm. The burner is set at an angle of 20° to the horizontal of the sample. Failure occurs when the cotton ignites or produces a sample greater than 100 mm (UL 1581, 1100.4) TABLE 1: COMPARATIVE AND INVENTIVE EXAMPLES CS = Comparative Sample IE = Inventive Example * failure = before week 10 to 12, the average resistance was measured below 1000 MOhms and the decay for consecutive weeks is greater than 4% TABLE 2: CATALYST MAIN BATCH

[00228] Inventive Examples 1 to 2 show flame retardancy (i.e., each passes the horizontal burn test) and each also has a wet IR greater than 1.10 ohms. In comparison, Comparative Samples 1 and 2, which contain a silica filler without a silicone-based polymer, have a wet IR greater than 1.00 ohms but fail the horizontal burn test. Comparative Sample 3 contains less than 5% by weight of the silicone-based polymer and fails the horizontal burn test. Comparative Samples 4 through 11 contain a filler other than silica and have a wet IR of less than 1.10 ohms.

[00229] It is specifically intended that the present disclosure is not limited to the embodiments and illustrations contained herein, but that it includes modified forms of these embodiments, including portions of the embodiments and combinations of elements of different embodiments, as they come within the scope of the claims. Next.

Claims (11)

1. Crosslinkable composition, characterized by the fact that it comprises: (A) a silane-functionalized polyolefin, wherein the silane-functionalized polyolefin is an ethylene-based polymer grafted with silane; (B) a filler comprising more than 50% by weight silica, based on the total weight of the filler, wherein the silica has an average particle size (D50) of 0.01 µm to 50 µm; (C) from 4% to 20% by weight of a silicone-containing polymer selected from the group consisting of linear non-reactive silicone-containing polymers and non-reactive branched silicone-containing polymer, wherein the silicone-containing polymer is a polysiloxane linear non-reactive; and (D) from 0.00% by weight to 20% by weight of a silanol condensation catalyst, based on the total weight of the crosslinkable composition. 2. Jacket layer for a coated conductor characterized by the fact that it comprises (A) a cross-linked silane-functionalized polyolefin, wherein the cross-linked silane-functionalized polyolefin is a silane-grafted ethylene-based polymer; (B) a filler comprising more than 50% by weight silica, based on the total weight of the filler, wherein the silica has an average particle size (D50) of 0.01 µm to 50 µm; (C) from 4% to 20% by weight of a silicone-containing polymer selected from the group consisting of linear non-reactive silicone-containing polymers and non-reactive branched silicone-containing polymer, wherein the silicone-containing polymer is a polysiloxane linear non-reactive; and (D) from 0.00% by weight to 10% by weight of a silanol condensation catalyst, based on the total weight of the crosslinkable composition. 3. Liner layer according to claim 2, characterized by the fact that the filler comprises more than 90% by weight to 100% by weight silica, based on the total weight of the load. 4. Jacket layer according to claim 3, characterized by the fact that the filler consists only of silica. 5. Liner layer according to claim 2, characterized by the fact that it comprises, based on the total weight of the liner layer, (A) from 20% by weight to 80% by weight of the cross-linked silane functionalized polyolefin, in that cross-linked silane-grafted polyolefin is a cross-linked silane-grafted polyethylene; (B) from 20% by weight to 80% by weight of the load; and (C) from 4% by weight to 20% by weight of the silicone-containing polymer. 6. Liner layer according to claim 2, characterized by the fact that the load comprises from 0% by weight to 0.5% by weight of metals, based on the total weight of the load. 7. The jacket layer of claim 6, wherein the jacket layer comprises from 0% by weight to 0.3% by weight of metals, based on the total weight of the load. 8. Shirt layer according to claim 2, characterized by the fact that it comprises from more than 4% by weight to 20% by weight of the silicone-containing polymer, based on the total weight of the shirt layer, wherein the layer of shirt has a wet insulation resistance ratio of 1.10 to 1.70. 9. The liner layer of claim 8, wherein the liner layer comprises from 4% by weight to 20% by weight of the silicone-containing polymer, based on the total weight of the liner layer, and the Shirt layer passes horizontal burning test. 10. Liner layer according to claim 2, characterized in that the liner layer further comprises at least one of a metal deactivator, a moisture scavenger and an antioxidant. 11. Shirt layer according to claim 2, characterized in that the shirt layer is an insulation layer.