US20190106557A1 - Crosslinkable polymeric compositions with methyl-radical scavengers and articles made therefrom - Google Patents

Crosslinkable polymeric compositions with methyl-radical scavengers and articles made therefrom Download PDF

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US20190106557A1
US20190106557A1 US16/088,336 US201616088336A US2019106557A1 US 20190106557 A1 US20190106557 A1 US 20190106557A1 US 201616088336 A US201616088336 A US 201616088336A US 2019106557 A1 US2019106557 A1 US 2019106557A1
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polymeric composition
crosslinkable polymeric
ethylene
peroxide
crosslinkable
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Yabin Sun
Jeffrey M. Cogen
Wei Li
Yu Cai
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Dow Global Technologies LLC
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    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
    • H01B3/18—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
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    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B9/00—Power cables
    • H01B9/02—Power cables with screens or conductive layers, e.g. for avoiding large potential gradients
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    • C08L2203/00—Applications
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    • C08L2207/00—Properties characterising the ingredient of the composition
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    • C08L2207/064—VLDPE
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    • C08L2312/00—Crosslinking

Definitions

  • the present disclosure relates to crosslinkable polymeric compositions comprising an ethylene-based polymer, an organic peroxide, a crosslinking coagent, and a methyl-radical scavenger comprising at least one derivative of 2,2,6,6-tetramethyl-1-piperidinyloxy (“TEMPO”), and articles made therefrom.
  • TEMPO 2,2,6,6-tetramethyl-1-piperidinyloxy
  • MV Medium voltage
  • HV high voltage
  • EHV extra-high voltage
  • MV Medium voltage
  • HV high voltage
  • EHV extra-high voltage
  • MV Medium voltage
  • HV high voltage
  • EHV extra-high voltage
  • MV Medium voltage
  • HV high voltage
  • EHV extra-high voltage
  • Such crosslinked polymeric materials can be prepared from a crosslinkable polymeric composition having a peroxide initiator. Crosslinking provides valuable improvements in the thermomechanical properties of the crosslinked polymeric material.
  • the peroxide initiators used for crosslinking do, however, create byproducts that require removal from the crosslinked polymeric material. For instance, when dicumyl peroxide is used as the peroxide initiator, the crosslinking reactions yield volatile byproducts such as acetophenone, cumyl alcohol, and methane. If not removed, these byproducts can negatively impact the quality of the cable comprising the crosslinked polymeric material. Byproduct removal must occur after the crosslinked polymeric material is formed into an insulation layer (e.g., by degassing) but before a jacketing layer is placed over the insulation layer.
  • an insulation layer e.g., by degassing
  • corch premature crosslinking
  • Crosslinkable polymeric compositions for use in, for example, cable insulation layers, are disclosed.
  • the crosslinkable polymeric compositions comprise, inter alia, an ethylene-based polymer, an organic peroxide, a crosslinking coagent, and a methyl-radical scavenger comprising at least one TEMPO derivative, wherein the ratio of crosslinking coagent to organic peroxide is less than 1.72:1 on a molar basis.
  • Inclusion of the at least one TEMPO derivative in the crosslinkable polymeric compositions provides a composition having improved properties, such as reduced byproduct offgassing, increased crosslink density, and improved scorch protection.
  • Crosslinked polymeric articles prepared from crosslinkable polymeric compositions are also disclosed, the crosslinkable polymeric compositions comprising, inter alia, a methyl-radical scavenger comprising at least one TEMPO derivative and a crosslinking coagent to organic peroxide ratio less than 1.72:1 on a molar basis.
  • coated conductors comprising a conductive core and a polymeric layer at least partially surrounding the conductive core are disclosed, wherein at least a portion of the polymeric layer comprises the crosslinked polymeric articles.
  • FIG. 1 is a plot of peak area versus methane used as a calibration curve for methane quantification.
  • ethylene-based polymers are polymers prepared from ethylene monomers as the primary (i.e., greater than 50 weight percent (“wt %”)) monomer component, though other comonomers may also be employed.
  • Polymer means a macromolecular compound prepared by reacting (i.e., polymerizing) monomers of the same or different type, and includes homopolymers and interpolymers.
  • Homopolymer means a polymer consisting of repeating units derived from a single monomer type, but does not exclude residual amounts of other components used in preparing the homopolymer, such as chain transfer agents.
  • Interpolymer means a polymer prepared by the polymerization of at least two different monomer types.
  • the generic term “interpolymer” includes copolymers, usually employed to refer to polymers prepared from two different monomer types, and polymers prepared from more than two different monomer types (e.g., terpolymers, quaterpolymers, and so on).
  • the ethylene-based polymer can be an ethylene homopolymer. In some embodiments, the ethylene-based polymer can be an ethylene/alpha-olefin (“ ⁇ -olefin”) interpolymer having an ⁇ -olefin content of at least 1 wt %, at least 5 wt %, at least 10 wt %, at least 15 wt %, at least 20 wt %, or at least 25 wt % based on the entire interpolymer weight.
  • ⁇ -olefin ethylene/alpha-olefin
  • interpolymers can have an ⁇ -olefin content of less than 50 wt %, less than 45 wt %, less than 40 wt %, or less than 35 wt % based on the entire interpolymer weight.
  • the ⁇ -olefin can be a C 3-20 (i.e., having 3 to 20 carbon atoms) linear, branched, or cyclic ⁇ -olefin.
  • C 3-20 ⁇ -olefins examples include propene, 1-butene, 4-methyl-1-pentene, 1-hexene, 1-octene, 1-decene, 1-dodecene, 1-tetradecene, 1-hexadecene, and 1-octadecene.
  • the ⁇ -olefins can also have a cyclic structure such as cyclohexane or cyclopentane, resulting in an ⁇ -olefin such as 3-cyclohexyl-1-propene (allyl cyclohexane) and vinyl cyclohexane.
  • Illustrative ethylene/ ⁇ -olefin interpolymers include ethylene/propylene, ethylene/1-butene, ethylene/1-hexene, ethylene/1-octene, ethylene/propylene/1-octene, ethylene/propylene/1-butene, and ethylene/1-butene/1-octene.
  • the ethylene-based polymer can be used alone or in combination with one or more other types of ethylene-based polymers (e.g., a blend of two or more ethylene-based polymers that differ from one another by monomer composition and content, catalytic method of preparation, etc.). If a blend of ethylene-based polymers is employed, the polymers can be blended by any in-reactor or post-reactor process.
  • the ethylene-based polymer can be selected from the group consisting of low-density polyethylene (“LDPE”), linear-low-density polyethylene (“LLDPE”), very-low-density polyethylene (“VLDPE”), and combinations of two or more thereof.
  • LDPE low-density polyethylene
  • LLDPE linear-low-density polyethylene
  • VLDPE very-low-density polyethylene
  • the ethylene-based polymer can be a LDPE.
  • LDPEs are generally highly branched ethylene homopolymers, and can be prepared via high pressure processes (i.e., HP-LDPE).
  • LDPEs suitable for use herein can have a density ranging from 0.91 to 0.94 g/cm 3 .
  • the ethylene-based polymer is a high-pressure LDPE having a density of at least 0.915 g/cm 3 , but less than 0.94 g/cm 3 , or less than 0.93 g/cm 3 .
  • Polymer densities provided herein are determined according to ASTM International (“ASTM”) method D792.
  • LDPEs suitable for use herein can have a melt index (I 2 ) of less than 20 g/10 min., or ranging from 0.1 to 10 g/10 min., from 0.5 to 5 g/10 min., from 1 to 3 g/10 min., or an I 2 of 2 g/10 min. Melt indices provided herein are determined according to ASTM method D1238. Unless otherwise noted, melt indices are determined at 190° C. and 2.16 Kg (i.e., I 2 ). Generally, LDPEs have a broad molecular weight distribution (“MWD”) resulting in a relatively high polydispersity index (“PDI;” ratio of weight-average molecular weight to number-average molecular weight).
  • MWD molecular weight distribution
  • PDI polydispersity index
  • the ethylene-based polymer can be a LLDPE.
  • LLDPEs are generally ethylene-based polymers having a heterogeneous distribution of comonomer (e.g., ⁇ -olefin monomer), and are characterized by short-chain branching.
  • LLDPEs can be copolymers of ethylene and ⁇ -olefin monomers, such as those described above.
  • LLDPEs suitable for use herein can have a density ranging from 0.916 to 0.925 g/cm 3 .
  • LLDPEs suitable for use herein can have a melt index (I 2 ) ranging from 1 to 20 g/10 min., or from 3 to 8 g/10 min.
  • the ethylene-based polymer can be a VLDPE.
  • VLDPEs may also be known in the art as ultra-low-density polyethylenes (“ULDPE”).
  • VLDPEs are generally ethylene-based polymers having a heterogeneous distribution of comonomer (e.g., ⁇ -olefin monomer), and are characterized by short-chain branching.
  • VLDPEs can be copolymers of ethylene and ⁇ -olefin monomers, such as one or more of those ⁇ -olefin monomers described above.
  • VLDPEs suitable for use herein can have a density ranging from 0.87 to 0.915 g/cm 3 .
  • VLDPEs suitable for use herein can have a melt index (I 2 ) ranging from 0.1 to 20 g/10 min., or from 0.3 to 5 g/10 min.
  • the ethylene-based polymer can contain one or more polar comonomers, such as acrylates or vinyl acetates. Additionally, blends of non-polar ethylene-based polymers, such as those described above, and polar copolymers (e.g., those copolymers containing one or more types of polar comonomers), may also be employed. Furthermore, polyolefin elastomers, such as those commercially available under the trade name ENGAGETM from The Dow Chemical Company, may be used as the ethylene-based polymer or in combination with one or more of the above-described ethylene-based polymers.
  • Polyolefin elastomers suitable for use herein can have a density ranging from 0.857 g/cm 3 to 0.908 g/cm 3 .
  • Polyolefin elastomers suitable for use herein can have a melt index (I 2 ) ranging from 0.1 to 30 g/10 min., or from 0.5 to 5 g/10 min.
  • the ethylene-based polymer can comprise a combination of any two or more of the above-described ethylene-based polymers.
  • Production processes used for preparing ethylene-based polymers are wide, varied, and known in the art. Any conventional or hereafter discovered production process for producing ethylene-based polymers having the properties described above may be employed for preparing the ethylene-based polymers described herein.
  • polymerization can be accomplished at conditions known in the art for Ziegler-Natta, chromium oxide, or Kaminsky-Sinn type polymerization reactions, that is, at temperatures from 0 to 250° C., or 30 or 200° C., and pressures from atmospheric to 10,000 atmospheres (approximately 1,013 MegaPascals (“MPa”)).
  • MPa MegaPascals
  • the molar ratio of catalyst to polymerizable compounds employed is from 10 ⁇ 12 :1 to 10-1:1, or from 10 ⁇ 9 :1 to 10 ⁇ 5 :1.
  • An example of an ethylene-based polymer suitable for use herein is low-density polyethylene having a density of 0.92 g/cm 3 and a melt index (I 2 ) of 2 g/10 min.
  • the crosslinkable polymeric composition further comprises an organic peroxide.
  • organic peroxide denotes a peroxide having the structure: R 1 —O—O—R 2 or R 1 —O—O—R—O—O—R 2 , where each of R 1 and R 2 is a hydrocarbyl moiety, and R is a hydrocarbylene moiety.
  • hydrocarbyl denotes a univalent group formed by removing a hydrogen atom from a hydrocarbon (e.g., ethyl, phenyl) optionally having one or more heteroatoms.
  • hydrocarbylene denotes a bivalent group formed by removing two hydrogen atoms from a hydrocarbon optionally having one or more heteroatoms.
  • the organic peroxide can be any dialkyl, diaryl, dialkaryl, or diaralkyl peroxide, having the same or differing alkyl, aryl, alkaryl, or aralkyl moieties.
  • each of R 1 and R 2 is independently a C 1 to C 20 or C 1 to C 12 alkyl, aryl, alkaryl, or aralkyl moiety.
  • R can be a C 1 to C 20 or C 1 to C 12 alkylene, arylene, alkarylene, or aralkylene moiety.
  • R, R 1 , and R 2 can have the same or a different number of carbon atoms and structure, or any two of R, R 1 , and R 2 can have the same number of carbon atoms while the third has a different number of carbon atoms and structure.
  • Organic peroxides suitable for use herein include mono-functional peroxides and di-functional peroxides.
  • “mono-functional peroxides” denote peroxides having a single pair of covalently bonded oxygen atoms (e.g., having a structure R—O—O—R).
  • di-functional peroxides denote peroxides having two pairs of covalently bonded oxygen atoms (e.g., having a structure R—O—O—R—O—O—R).
  • the organic peroxide is a mono-functional peroxide.
  • Exemplary organic peroxides include dicumyl peroxide (“DCP”), tert-butyl peroxybenzoate, di-tert-amyl peroxide (“DTAP”), bis(alpha-t-butyl-peroxyisopropyl) benzene (“BIPB”), isopropylcumyl t-butyl peroxide, t-butylcumylperoxide, di-t-butyl peroxide, 2,5-bis(t-butylperoxy)-2,5-dimethylhexane, 2,5-bis(t-butylperoxy)-2,5-dimethylhexyne-3, 1,1-bis(t-butylperoxy)-3,3,5-trimethylcyclohexane, isopropylcumyl cumylperoxide, butyl 4,4-di(tert-butylperoxy) valerate, di(isopropylcumyl) peroxide, and combinations of two
  • the crosslinkable polymeric composition further comprises a crosslinking coagent.
  • crosslinking coagents include polyallyl crosslinking coagents such as triallyl isocyanurate (“TAIC”), triallyl cyanurate (“TAC”), triallyl trimellitate (“TATM”), N2,N2,N4,N4,N6,N6-hexaallyl-1,3,5-triazine-2,4,6-triamine (“HATATA”), triallyl orthoformate, pentaerythritol triallyl ether, triallyl citrate, and triallyl aconitate, ⁇ -methyl styrene dimer (“AMSD”), acrylate-based coagents such as trimethylolpropane triacrylate (“TMPTA”), trimethylolpropane trimethylacrylate (“TMPTMA”), ethoxylated bisphenol A dimethacrylate, 1,6-hexanediol diacrylate, pentaerythritol
  • the crosslinkable polymeric composition further comprises a methyl-radical scavenger comprising at least one derivative of 2,2,6,6-tetramethyl-1-piperidinyloxy (“TEMPO”) having a structure of formula (I)
  • TEMPO 2,2,6,6-tetramethyl-1-piperidinyloxy
  • derivatives of TEMPO include, for example, 4-acryloxy-2,2,6,6-tetramethylpiperidine-N-oxyl (“acrylate TEMPO”) having a structure of formula (II) (CAS: 21270-85-9)
  • allyl TEMPO 4-allyloxy-2,2,6,6-tetramethylpiperidine-N-oxyl having a structure of formula (III), (CAS: 217496-13-4)
  • bis TEMPO bis(2,2,6,6-tetramethyl-1-piperidinyloxy-4-yl) sebacate having a structure of formula (IV), (CAS: 2516-92-9)
  • the methyl-radical scavenger can comprise a TEMPO derivative selected from any one of acrylate TEMPO, allyl TEMPO, or bis TEMPO, and combinations of two or more thereof.
  • the crosslinkable polymeric composition can comprise the ethylene-based polymer in an amount ranging from 1 to 99.9 wt %, from 90 to 99.9 wt %, or from 97.72 to 98.6 wt %, based on the entire crosslinkable polymeric composition weight.
  • the crosslinkable polymeric composition can comprise the organic peroxide in an amount ranging from 0.1 to 3 wt %, from 0.1 to 2 wt %, or from 0.1 to 0.95 wt %, based on the entire crosslinkable polymeric composition weight.
  • the crosslinkable polymeric composition can comprise the crosslinking coagent in an amount ranging from 0.1 to 5.2 wt %, from 0.2 to 1 wt %, or from 0.4 to 0.5 wt %, based on the entire crosslinkable polymeric composition weight. Still further, the crosslinkable polymeric composition can comprise the methyl-radical scavenger in an amount ranging from 0.05 to 10 wt %, from 0.16 to 5 wt %, from 0.5 to 1 wt %, or from 0.68 to 0.72 wt %, based on the entire crosslinkable polymeric composition weight.
  • the ratio of crosslinking coagent and organic peroxide is equal to or less than 1.72:1 on a molar basis (i.e., moles crosslinking coagent/moles organic peroxide), equal to or less than 1.08:1 on a molar basis, or equal to or less than 0.51:1 on a molar basis.
  • the crosslinkable polymeric composition may also contain one or more additives including, but not limited to, scorch retardants, antioxidants, processing aids, fillers, coupling agents, ultraviolet absorbers or stabilizers, antistatic agents, nucleating agents, slip agents, plasticizers, lubricants, viscosity control agents, tackifiers, anti-blocking agents, surfactants, extender oils, acid scavengers, flame retardants, water tree retardants, electrical tree retardants, voltage stabilizers, and metal deactivators.
  • additives including, but not limited to, scorch retardants, antioxidants, processing aids, fillers, coupling agents, ultraviolet absorbers or stabilizers, antistatic agents, nucleating agents, slip agents, plasticizers, lubricants, viscosity control agents, tackifiers, anti-blocking agents, surfactants, extender oils, acid scavengers, flame retardants, water tree retardants, electrical tree retardants, voltage stabilizers, and metal deactivators.
  • Fillers are generally added in larger amounts, although the amount can range from as low as 0.01 or less to 65 or more wt % based on the total composition weight.
  • Illustrative examples of fillers include clays, precipitated silica and silicates, fumed silica, calcium carbonate, ground minerals, aluminum trihydroxide, magnesium hydroxide, and carbon blacks with typical arithmetic mean particle sizes larger than 15 nanometers.
  • exemplary antioxidants include hindered phenols (e.g., tetrakis [methylene (3,5-di-t-butyl-4-hydroxyhydrocinnamate)] methane), less-hindered phenols, and semi-hindered phenols, phosphates, phosphites, and phosphonites (e.g., tris (2,4-di-t-butylphenyl) phosphate), thio compounds (e.g., distearyl thiodipropionate, dilauryl thiodipropionate), various siloxanes, and various amines (e.g., polymerized 2,2,4-trimethyl-1,2-dihydroquinoline).
  • hindered phenols e.g., tetrakis [methylene (3,5-di-t-butyl-4-hydroxyhydrocinnamate)] methane
  • less-hindered phenols e.g.,
  • the antioxidant is selected from the group consisting of distearyl thiodipropionate, dilauryl thiodipropionate, octadecyl-3,5-di-t-butyl-4-hydroxyhydrocinnamate, benzenepropanoic acid, 3,5-bis(1,1-dimethylethyl)-4-hydroxy-thiodi-2,1-ethanediyl ester, stearyl 3-(3,5-di-t-butyl-4-hydroxyphenyl) propionate, octadecyl-3-(3,5-di-tert-butyl-4-hydroxyphenyl)-propionate, 2,4-bis(dodecylthiomethyl)-6-methylphenol, 4,4′-thiobis(6-tert-butyl-m-cresol), 4,6-bis(octylthiomethyl)-o-cresol, 1,3,5-tris(4-
  • antioxidants suitable for use in the disclosed crosslinkable polymeric materials include CYANOXTM 1790 available from the Cytec Solvay Group and IRGANOXTM PS 802 available from BASF SE. Suitable antioxidants may also comprise hindered amine light stabilizers (“HALS”).
  • HALS hindered amine light stabilizers
  • Antioxidants when present, can be used in amounts ranging from 0.01 to 5 wt %, from 0.01 to 1 wt %, from 0.1 to 5 wt %, from 0.1 to 1 wt %, or from 0.1 to 0.5 wt %, based on the total weight of the crosslinkable polymeric composition.
  • Preparation of the cross-linkable polymeric composition can comprise compounding the above-described components.
  • compounding can be performed by either (1) compounding all components into the ethylene-based polymer, or (2) compounding all the components except for one or more of the organic peroxide, one or more of crosslinking coagent, and one or more of methyl-radical scavenger, which can be soaked in as described below.
  • Compounding of the crosslinkable polymeric composition can be effected by standard equipment known to those skilled in the art. Examples of compounding equipment are internal batch mixers, such as a BrabenderTM, BanburyTM, or BollingTM mixer.
  • continuous single or twin screw, mixers can be used, such as a FarrelTM continuous mixer, a Werner and PfleidererTM twin screw mixer, or a BussTM kneading continuous extruder.
  • Compounding can be performed at a temperature of greater than the melting temperature of the ethylene-based polymer up to a temperature above which the ethylene-based polymer begins to degrade. In some embodiments, compounding can be performed at a temperature ranging from 100 to 200° C., or from 110 to 150° C.
  • the ethylene-based polymer and any optional components can first be melt compounded according to the above-described procedure and pelletized. Next, the organic peroxide, the crosslinking coagent, and the methyl-radical scavenger comprising at least one TEMPO derivative can be soaked into the resulting ethylene-based polymer compound, either simultaneously or sequentially.
  • one or more of the organic peroxide, the coagent, and the TEMPO derivative can be premixed at the temperature above the melting temperature of the organic peroxide, the coagent, and the TEMPO derivative, whichever is greatest or above the melt temperature of the corresponding mixture, followed by soaking the ethylene-based polymer compound in the resulting mixture of the organic peroxide, the crosslinking coagent, and the TEMPO derivative at a temperature ranging from 30 to 100° C., from 50 to 90° C., or from 60 to 80° C., for a period of time ranging from 1 to 168 hours, from 1 to 24 hours, or from 3 to 12 hours.
  • the resulting crosslinkable polymeric composition can have certain enhanced properties. Though not wishing to be bound by theory, it is believed that utilizing a disclosed crosslinking coagent together with a methyl-radical scavenger comprising at least one TEMPO derivative can surprisingly provide superior curing and scorch resistance properties as well as decreased undesired byproduct generation.
  • crosslinkable polymeric compositions can be cured or allowed to cure in order to form a crosslinked polymeric composition.
  • Such curing can be performed by subjecting the crosslinkable polymeric composition to elevated temperatures in a heated cure zone, which can be maintained at a temperature in the range of 175 to 260° C.
  • the heated cure zone can be heated by pressurized steam or inductively heated by pressurized nitrogen gas. Thereafter, the crosslinked polymeric composition can be cooled (e.g., to ambient temperature).
  • the crosslinking process can create volatile decomposition byproducts in the crosslinked polymeric composition.
  • the crosslinked polymeric composition can undergo degassing to remove at least a portion of the volatile decomposition byproducts.
  • Degassing can be performed at a degassing temperature, a degassing pressure, and for a degassing time period to produce a degassed polymeric composition.
  • the degassing temperature can range from 50 to 150° C., or from 60 to 80° C. In some embodiments, the degassing temperature is 65 to 75° C.
  • Degassing can be conducted under standard atmosphere pressure.
  • the initial cable core containing inner and outer semiconductive and insulation layers can be prepared with various types of extruders, e.g., single or twin screw types.
  • extruders e.g., single or twin screw types.
  • a description of a conventional extruder can be found in U.S. Pat. No. 4,857,600.
  • An example of co-extrusion and an extruder therefore can be found in U.S. Pat. No. 5,575,965.
  • a typical extruder has a hopper at its upstream end and a die at its downstream end. The hopper feeds into a barrel, which contains a screw. At the downstream end, between the end of the screw and the die, there is a screen pack and a breaker plate.
  • the screw portion of the extruder is considered to be divided up into three sections, the feed section, the compression section, and the metering section, and two zones, the back heat zone and the front heat zone, the sections and zones running from upstream to downstream.
  • the length to diameter ratio of each barrel is in the range of about 15:1 to about 30:1.
  • the resulting initial cable core can undergo a crosslinking process to crosslink the insulation and both inner and outer semiconductive layers.
  • the initial cable core can be passed into a heated cure zone downstream of the extrusion die.
  • the heated cure zone can be maintained at a temperature in the range of about 150 to about 350° C., or in the range of about 170 to about 250° C.
  • the heated cure zone can be heated by pressurized steam, or inductively heated pressurized nitrogen gas.
  • the cable core having a crosslinked insulation, inner, and outer semiconductive layers can be cooled (e.g., to room temperature).
  • the crosslinking process can create volatile decomposition byproducts in the crosslinked insulation layer.
  • volatile decomposition products denotes decomposition products formed during the curing step, and possibly during the cooling step, by decomposition and reaction of the free radical generating agent (e.g., dicumyl peroxide).
  • free radical generating agent e.g., dicumyl peroxide
  • Such byproducts can comprise alkanes, such as methane.
  • Additional byproducts can include alcohols.
  • Such alcohols can comprise the alkyl, aryl, alkaryl, or aralkyl moieties of the above-described organic peroxide.
  • the byproduct alcohol is cumyl alcohol.
  • Other decomposition products can include ketone byproducts from the above-described organic peroxide.
  • acetophenone is a decomposition byproduct of dicumyl peroxide.
  • the crosslinked insulation layer can undergo degassing to remove at least a portion of volatile decomposition byproducts.
  • Degassing can be performed at a degassing temperature, a degassing pressure, and for a degassing time period to produce a degassed cable core.
  • the degassing temperature can range from 50 to 150° C., or from 60 to 80° C. In an embodiment, the degassing temperature is 65 to 75° C.
  • Degassing can be conducted under standard atmospheric pressure (i.e., 101,325 Pa).
  • Alternating current cables can be prepared according to the present disclosure, which can be LV, MV, HV, or EHV cables. Further, direct current cables can be prepared according to the present disclosure, which can include high or extra-high voltage cables.
  • LDPE low-density polyethylene
  • I 2 melt index
  • LDPE 1 is produced by The Dow Chemical Company and contains 0.13% distearyl thiodipropionate (“DSTDP”), 0.09% CYANOXTM 1790 and about 20 ppm UVINUL 4050.
  • LDPE 2 is produced by The Dow Chemical Company and contains 0.09% DSTDP, 0.06% CYANOXTM 1790 and about 14 ppm UVINUL 4050.
  • CYANOXTM 1790 is a commercially available antioxidant having the chemical name 1,3,5-tris(4-tert-butyl-3-hydroxy-2,6-dimethylbenzyl)-1,3,5-triazine-2,4,6-trione, available from Cytec Industries. It is used as received.
  • DSTDP Disteayl thiodipropionate
  • Cytec Cytec
  • UVINULTM 4050 is a commercially available UV stabilizer having the chemical name 1,6-hexamethylenebis[N-formyl-N-(2,2,6,6-tetramethylpiperidin-4-yl)amine], available from BASF. It is used as received.
  • DCP Dicumyl peroxide
  • TIC Triallyl isocyanurate
  • TAC Triallyl cyanurate
  • TATM triallyl trimellitate
  • TMPTA and TMPTMA are commercially available from Sartomer. Both are used as received.
  • HATATA is prepared by adding 3.69 g (0.02 mol) cyanuric acid and 8.90 g (0.064 mol) sodium carbonate into 30 g of 1,4-dioxane in a three-neck flask. While stirring, heat the mixture to 75° C., and stir for an additional 5 minutes upon reaching 75° C. Next, gradually add 10.22 g (0.1 mol) diallylamine dropwise over about 15 minutes, then add 2.8 g of sodium hydroxide (0.07 mol) and raise the temperature to about 90° C. Keep the reaction mixture at 90° C. for 5 hours. Thereafter, cool the reaction mixture to room temperature and filter using vacuum filtration with a sand-core funnel to remove insoluble salts.
  • the resulting filtrate is distilled under reduced pressure to recover the solvent, and the residue is dissolved in petroleum ether and further purified through silica gel column. This is performed by first transferring the liquid filtrate from the flask to the silica gel column and use 2 mL of petroleum ether to wash the flask and transfer the solution to the silica gel.
  • the silica gel is 300 mesh and is used as the stationary phase; the petroleum ether is used as the eluent.
  • TEMPO is commercially available from TCI. It is used as received.
  • Bis TEMPO is commercially available from Ningbo Sialon Chem. Co. Ltd. It is used as received.
  • Acrylate TEMPO can be prepared by known techniques, such as those disclosed in Hyslop D. K., Parent J. S., Macromolecules, 2012; 45, 8147-8154. For instance, acryloyl chloride (632 mg, 0.57 mL, 6.98 mmol) in toluene (2.03 mL) was added dropwise to a solution of 4-hydroxyl TEMPO (4-hydroxyl-2,2,6,6-tetramethyl-1-piperidinyloxy) (1 g, 5.81 mmol) and triethylamine (706 mg, 0.97 mL, 6.98 mmol) in toluene (14.4 mL), and the mixture was stirred at room temperature for 16 h. The resulting solution was filtered before removing solvent under vacuum, yielding orange crystals that were recrystallized from cyclohexane.
  • Allyl TEMPO can be prepared by adding 1.2 equivalents of sodium hydride to a solution of 1 equivalent of TEMPO in tetrahydrofuran. Allyl brodmide is added dropwise to the solution and the mixture is stirred at reflux for 12 hours. The mixture is then quenched by addition of saturated ammonium chloride and extracted with ethyl acetate. The combined organic layers are then washed with brine, dried over sodium sulfate, and concentrated under reduced pressure. The crude material is purified by flash column chromatography to obtain the allyl TEMPO.
  • MDR moving die rheometer
  • ts1@140° C. is the scorch time of sample X measured by MDR at 140° C.
  • ts1′@140° C. is the predicted scorch for sample X but having no methyl-radical scavenger and no crosslinking coagents, where the prediction is based on the crosslink density (MH ⁇ ML) of sample X.
  • the predicted scorch time is calculated according to equation (2) below:
  • Equation (MH ⁇ ML)@180° C. is the crosslink density of sample X measured by MDR at 180° C. Equation (I) is determined based on comparison of five samples prepared without a methyl-radical scavenger and crosslinking coagents to determine the relationship between scorch time and crosslink density for samples having no crosslinking coagent and no methyl-radical scavenger.
  • Equation (2) is the relationship between crosslink density (MH ⁇ ML)@180° C. and scorch time (ts1′@140° C.) of the sample containing no methyl-radical scavenger and no crosslinking coagents. Therefore, the scorch time (ts1′@140° C.) of the sample with no methyl-radical scavenger and no crosslinking coagents (ts1′@140° C.) at a given crosslink density (MH ⁇ ML)@180° C. can be predicted by this equation.
  • the SI value suggests how the addition of both a crosslinking coagents and a methyl-radical scavenger will impact the scorch time compared to the sample without both the crosslinking coagent and methyl-radical scavenger.
  • a negative value means reduced the anti-scorch property, while a positive value means improved anti-scorch property, with the greater the positive value the better.
  • G1888 Headspace Conditions GC cycle time 30 minutes Oven temperature 150° C. Loop temperature 180° C. Transfer line temperature 190° C. Vial equilibration time 30 minutes Shaking speed Off Loop fill time 0.20 minutes Loop equilibration time 0.10 minutes Inject time 0.50 minutes Pressurization time 0.50 minutes Advance functions Multi HS EXT on; 5 extractions per vial
  • a 1 is the peak area or analyte amount of the first extraction.
  • K is the slope of a linear relationship predicted between the sequence number of extraction and the corresponding natural logarithm of peak area or analyte amount. If the sample is a suitable system for application of multiple headspace extraction, a good fit will be observed between extraction number and the logarithm of peak area.
  • the methane concentration in plaque is calculated according calibration curve, correlation between peak area and methane concentration.
  • the effect of the coagent to peroxide ratio on the crosslinkable compositions is determined by preparing CEs and IEs according to the formulations provided in Table 2, below, and using the materials described above and the sample preparation methods below.
  • Three Illustrative Samples (IE1-IE3) and three Comparative Samples (CE1-CE3) are prepared according to the formulations provided in Table 2 below by soaking DCP and TAIC, with or without acrylate TEMPO, into LDPE1 pellets at 80° C. for 8 hours.
  • CE1-CE3 and IE1-IE3 Properties CE1 IE1 CE2 IE2-1 CE3 IE3 ML, dN*m 0.22 0.20 0.22 0.19 0.22 0.18 MH, dN*m 3.71 3.55 3.82 3.63 3.26 3.32 MH-ML, 3.49 3.35 3.60 3.44 3.04 3.14 dN*m ts1 @ 180° 1.16 1.36 1.08 1.23 1.38 1.62 C., min. T90 @ 180° 4.27 4.52 4.16 4.30 4.80 5.163 C., min. Methane, ppm 301 273 385 336 205 209 ⁇ Methane, ⁇ 28 ⁇ 49 4 ppm
  • CE1 and IE1 each contain identical formulations except that IE1 includes acrylate TEMPO and reduced ethylene-based polymer in a corresponding amount. IE1 exhibits comparable crosslink density, improved scorch times, and a nearly 10 percent decrease in methane production.
  • CE2 and IE2-1 contain identical formulations except that IE2-1 includes acrylate TEMPO and reduced ethylene-based polymer in a corresponding amount. IE2-1 exhibits comparable crosslink density, improved scorch times, and a nearly 13 percent decrease in methane production.
  • the effect of various coagents on the crosslinkable compositions is determined by preparing CEs and IEs according to the formulations provided in Table 4, below, and using the materials described above and the sample preparation methods below.
  • Six Illustrative Samples (IE2-2, IE4-IE8) and six Comparative Samples (CE2, CE4 CE8) are prepared according to the formulations provided in Table 4 below by soaking DCP and coagents, with or without acrylate TEMPO, into LDPE1 pellets at 80° C. for 8 hours.
  • CE2 IE2-2 CE4 IE4 CE5 IE5 CE6 IE6 CE7 IE7 CE8 IE8 ML, dN*m 0.22 0.18 0.28 0.18 0.21 0.18 0.23 0.18 0.23 0.19 0.23 0.18 MH, dN*m 3.82 2.90 2.60 2.66 2.32 2.30 3.46 3.21 2.86 2.79 3.29 3.40 MH-ML, dN*m 3.60 2.72 2.32 2.48 2.11 2.12 3.23 3.03 2.63 2.60 3.06 3.22 ts1 @ 180° C., min.
  • the results from Table 5 show that the addition of acrylate TEMPO to a composition comprising a crosslinking coagent, with a coagent to peroxide ratio of less than 1.72:1, provides for crosslinkable compositions exhibiting decreased methane production, comparable crosslink density, and improved scorch resistance.
  • the IEs in Table 5 each comprise acrylate TEMPO whereas the CEs do not.
  • the IEs exhibited comparable crosslink density, improved scorch times, and decreases in methane production.
  • the effect of various TEMPO derivatives on the crosslinkable compositions is determined by preparing CEs and IEs according to the formulations provided in Table 6, below, and using the materials described above and the sample preparation methods below.
  • Two Illustrative Samples (IE2-2 and IE9) and two Comparative Samples (CE2 and CE9) are prepared according to the formulations provided in Table 6 below by soaking DCP and TAIC, with or without TEMPO derivatives, into LDPE1 pellets at 80° C. for 8 hours.
  • IE10 is prepared by first blending the LDPE 1 and bis TEMPO in a Brabender mixer at 125° C. and a rotor speed of 30 rpm. The resulting compound is extruded through a single-screw extruder at 125° C. and pelletized. Then DCP and TAIC are soaked into the pellets at 80° C. for 8 hours.
  • TEMPO derivatives i.e., acrylate TEMPO, allyl TEMPO, and bis TEMPO
  • these TEMPO derivatives provide for crosslinkable compositions exhibiting decreased methane production, improved crosslink density, and improved scorch resistance.
  • Additional Examples are prepared according to the formulations provided in Table 8, below, and using the materials described above and the sample preparation methods below.
  • Four Illustrative Samples (IE2-2, 2-3, 24 and IE11) and two Comparative Samples (CE2 and CE10) are prepared according to the formulations provided in Table 8 below by soaking DCP and coagents, with or without TEMPO derivatives, into LDPE1 or LDPE 2 pellets at 80° C. for 8 hours.
  • CE2 IE2-2 IE2-3 IE2-4 CE10 IE11 ML, dN*m 0.22 0.18 0.18 0.19 0.19 0.17 MH, dN*m 3.82 2.90 3.54 3.02 3.21 2.90 MH-ML, 3.60 2.72 3.36 3.36 3.02 2.73 dN*m ts1 @ 180° 1.08 2.27 1.63 1.92 1.39 1.92 C., min. T90 @ 180° 4.16 5.91 5.06 5.34 4.67 5.43 C., min. Methane, ppm 385 208 281 216 194 160 ⁇ methane, ppm ⁇ 177 ⁇ 104 ⁇ 169 34

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