POLYMERIC COMPOSITION CONTAINING A LIGHT STABILIZER
20210189109 · 2021-06-24
Inventors
- Bharat I. Chaudhary (Princeton, NJ)
- Xindi Yu (Phoenixville, PA, US)
- Yichi Zhang (Novi, MI, US)
- Peter C. Dreux (Lumberton, NJ, US)
Cpc classification
C08K5/0066
CHEMISTRY; METALLURGY
C08L23/0892
CHEMISTRY; METALLURGY
C08K2201/019
CHEMISTRY; METALLURGY
C08L23/0892
CHEMISTRY; METALLURGY
C08L43/04
CHEMISTRY; METALLURGY
C09D123/0892
CHEMISTRY; METALLURGY
C08K5/34926
CHEMISTRY; METALLURGY
C08K5/005
CHEMISTRY; METALLURGY
C08K5/34926
CHEMISTRY; METALLURGY
C08L51/06
CHEMISTRY; METALLURGY
C08L51/06
CHEMISTRY; METALLURGY
International classification
C08L43/04
CHEMISTRY; METALLURGY
Abstract
The present disclosure provides a composition. The composition includes a silane functionalized polyolefin; a flame retardant; and a hindered amine light stabilizer (HALS) having a Mw greater than 5,000 Dalton. The present disclosure also provides a coated conductor. The coated conductor includes a conductor and a coating on the conductor, the coating including a composition. The coating composition includes a silane functionalized polyolefin; a flame retardant; and a hindered amine light stabilizer (HALS) having a Mw greater than 5,000 Dalton.
Claims
1. A composition comprising: a silane functionalized polyolefin; a flame retardant; and a hindered amine light stabilizer (HALS) having a weight average molecular weight, Mw, greater than 5,000 Dalton (g/mol).
2. The composition of claim 1, wherein the composition yields a wet insulation resistance (IR) ratio from 0.4 to 20.0.
3. The composition of claim 1, wherein the HALS has a Mw from greater than 5,000 Dalton to 50,000 Dalton.
4. The composition of claim 1, wherein the HALS has a Structure (H): ##STR00008## wherein m is an integer from 3 to 20.
5. The composition of claim 1, wherein the silane functionalized polyolefin is selected from the group consisting of a silane-grafted ethylene-based polymer and an ethylene/silane copolymer.
6. The composition of claim 1, wherein the flame retardant is a halogen-free flame retardant.
7. The composition of claim 1 comprising: from 20 wt % to 80 wt % of the silane functionalized polyolefin selected from the group consisting of a silane-grafted ethylene-based polymer and an ethylene/silane copolymer; from 20 wt % to 80 wt % of the halogen-free flame retardant; and from 0.1 wt % to 0.5 wt % of the HALS, based on the total weight of the composition.
8. The composition of claim 1 wherein the composition is halogen-free.
9. The composition of claim 1, wherein the flame retardant is a halogenated flame retardant.
10. (canceled)
11. A coated conductor comprising: a conductor; and a coating on the conductor, the coating comprising the composition of claim 1.
12. (canceled)
13. (canceled)
14. (canceled)
15. (canceled)
16. (canceled)
17. (canceled)
18. (canceled)
19. (canceled)
Description
DETAILED DESCRIPTION
[0071] The present disclosure provides a composition suitable for wire and cable applications. The composition includes: a silane functionalized polyolefin; a flame retardant; a hindered amine light stabilizer (HALS) having a having a weight average molecular weight, Mw, greater than 5,000 Dalton (g/mol); and optionally, an additive.
[0072] In an embodiment, the composition includes: a silane functionalized polyolefin; a halogen-free flame retardant; a hindered amine light stabilizer (HALS) having a having a weight average molecular weight, Mw, greater than 5,000 Dalton (g/mol); and optionally, an additive.
[0073] A. Silane Functionalized Polyolefin
[0074] The present composition includes a silane functionalized polyolefin. A “silane functionalized polyolefin” is a polymer that contains silane and equal to or greater than 50 wt %, or a majority amount, of polymerized α-olefin, based on the total weight of the polymer. Nonlimiting examples of suitable silane functionalized polyolefin include α-olefin/silane copolymer, silane-grafted polyolefin (Si-g-PO), and combinations thereof.
[0075] An “α-olefin/silane copolymer” is formed by the copolymerization of an α-olefin (such as ethylene) and a hydrolysable silane monomer (such as a vinyl alkoxysilane monomer). In an embodiment, the α-olefin/silane copolymer is an ethylene/silane copolymer prepared by the copolymerization of ethylene, a hydrolysable silane monomer and, optionally, an unsaturated ester. The preparation of ethylene/silane copolymers is described, for example, in U.S. Pat. Nos. 3,225,018 and 4,574,133, each incorporated herein by reference.
[0076] A “silane-grafted polyolefin” (or “Si-g-PO”) is formed by grafting a hydrolysable silane monomer (such as a vinyl alkoxysilane monomer) onto the backbone of a base polyolefin (such as polyethylene). In an embodiment, grafting takes place in the presence of a free-radical generator, such as a peroxide. The hydrolysable silane monomer can be grafted to the backbone of the base polyolefin (i) prior to incorporating or compounding the Si-g-PO into a composition used to make a final article, such as a coated conductor (also known as a SIOPLAS™ process), or (ii) simultaneously with the extrusion of a composition to form a final article (also known as a MONOSIL™ process, in which the Si-g-PO is formed in situ during melt blending and extrusion). In an embodiment, the Si-g-PO is formed before the Si-g-PO is compounded with a halogen-free flame retardant, HALS, and other optional components. In another embodiment, the Si-g-PO is formed in situ by compounding a polyolefin, hydrolysable silane monomer, peroxide initiator, and silanol condensation catalyst along with a halogen-free flame retardant, HALS, and other optional components.
[0077] The base polyolefin for the Si-g-PO may be an ethylene-based polymer or a propylene-based polymer. In an 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 polymers include ethylene homopolymers and ethylene-based interpolymers containing one or more polymerizable comonomers, such as an unsaturated ester and/or an α-olefin.
[0078] The hydrolysable silane monomer used to make an α-olefin/silane copolymer or a Si-g-PO is a silane-containing monomer that will effectively copolymerize with an α-olefin (e.g., ethylene) to form an α-olefin/silane copolymer (e.g., an ethylene/silane copolymer) or graft to an α-olefin polymer (e.g., a polyolefin) to form a Si-g-PO. Exemplary hydrolysable silane monomers are those having the following Structure (A):
##STR00001##
wherein R′ is a hydrogen atom or methyl group; x and y are 0 or 1 with the proviso that when x is 1, y is 1; n is an integer from 1 to 12 inclusive, or n is an integer from 1 to 4, and each R independently is a hydrolysable 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 from 1 to 12 carbon atoms (e.g., formyloxy, acetyloxy, propanoyloxy), amino or substituted amino groups (alkylamino, arylamino), or a lower alkyl group having 1 to 6 carbon atoms inclusive, with the proviso that not more than one of the three R groups is an alkyl.
[0079] Nonlimiting examples of suitable hydrolysable silane monomers include silanes that have an ethylenically unsaturated hydrocarbyl group, such as vinyl, allyl, isopropenyl, butenyl, cyclohexenyl or gamma-(meth)acryloxy allyl group, and a hydrolysable group, such as, for example, a hydrocarbyloxy, hydrocarbonyloxy, or hydrocarbylamino group. Examples of hydrolysable groups include methoxy, ethoxy, formyloxy, acetoxy, propionyloxy, and alkyl or arylamino groups.
[0080] In an embodiment, the hydrolysable silane monomer is an unsaturated alkoxysilane such as vinyl trimethoxysilane (VTMS), vinyl triethoxysilane, vinyl triacetoxy silane, gamma-(meth)acryloxy, propyl trimethoxy silane, and mixtures of these silanes.
[0081] Nonlimiting examples of suitable unsaturated esters used to make an α-olefin/silane copolymer include alkyl acrylate, alkyl methacrylate, or vinyl carboxylate. Nonlimiting examples of suitable alkyl groups include methyl, ethyl, n-propyl, i-propyl, n-butyl, t-butyl, etc. In an embodiment, the alkyl group has from 1, or 2 to 4, or 8 carbon atoms. Nonlimiting examples of suitable alkyl acrylates include ethyl acrylate, methyl acrylate, t-butyl acrylate, n-butyl acrylate, and 2-ethylhexyl acrylate. Nonlimiting examples of suitable alkyl methacrylates include methyl methacrylate and n-butyl methacrylate. In an embodiment, the carboxylate group has from 2 to 5, or 6, or 8 carbon atoms. Nonlimiting examples of suitable vinyl carboxylates include vinyl acetate, vinyl propionate, and vinyl butanoate.
[0082] In an embodiment, the silane functionalized polyolefin contains from 0.1 wt %, or 0.3 wt %, or 0.5 wt %, or 0.8 wt %, or 1.0 wt %, or 1.2 wt %, or 1.5 wt %, or 1.6 wt % to 1.8 wt %, or 2.0 wt %, or 2.3 wt %, or 2.5 wt %, or 3.0 wt %, or 3.5 wt %, or 4.0 wt %, or 4.5 wt %, or 5.0 wt % silane, based on the total weight of the silane functionalized polyolefin.
[0083] In an embodiment, the silane functionalized polyolefin has a density from 0.850 g/cc, or 0.860 g/cc, or 0.875 g/cc, or 0.890 g/cc to 0.900 g/cc, or 0.910 g/cc, or 0.915 g/cc, or 0.920 g/cc, or 0.930 g/cc, or 0.940 g/cc, or 0.950 g/cc or 0.960 g/cc, or 0.965 g/cc.
[0084] In an 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 wt %, or a majority amount, of polymerized ethylene, based on the total weight of the polymer.
[0085] In an embodiment, the silane functionalized polyethylene contains (i) from 50 wt %, or 55 wt %, or 60 wt %, or 65 wt %, or 70 wt %, or 80 wt %, or 90 wt %, or 95 wt % to 97 wt %, or 98 wt %, or 99 wt %, or less than 100 wt % ethylene and (ii) from 0.1 wt %, or 0.3 wt % or 0.5 wt %, or 0.8 wt %, or 1.0 wt %, or 1.2 wt %, or 1.5 wt %, or 1.6 wt % to 1.8 wt %, or 2.0 wt %, or 2.3 wt %, or 2.5 wt %, or 3.0 wt %, or 3.5 wt %, or 4.0 wt %, or 4.5 wt %, or 5.0 wt % silane, based on the total weight of the silane functionalized polyethylene.
[0086] In an embodiment, the silane functionalized polyethylene has a melt index (MI) from 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 70 g/10 min, or 80 g/10 min, or 90 g/10 min.
[0087] In an embodiment, the silane functionalized polyethylene is an ethylene/silane copolymer. The ethylene/silane copolymer contains ethylene and the hydrolyzable silane monomer as the only monomeric units. In another embodiment, the ethylene/silane copolymer optionally includes a C.sub.3, or C.sub.4 to C.sub.6, or C.sub.8, or C.sub.10, or C.sub.12, or C.sub.16, or C.sub.18, or C.sub.20 α-olefin; an unsaturated ester; and combinations thereof. In an embodiment, the ethylene/silane copolymer is an ethylene/unsaturated ester/silane reactor copolymer. Non-limiting examples of suitable ethylene/silane copolymers include SI-LINK™ DFDA-5451NT and SI-LINK™ AC DFDB-5451NT, each available from The Dow Chemical Company.
[0088] The α-olefin/silane reactor copolymer, and further the ethylene/silane reactor copolymer may comprise two or more embodiments disclosed herein.
[0089] In an embodiment, the silane functionalized polyethylene is a Si-g-PE.
[0090] The base ethylene-based polymer for the Si-g-PE includes from 50 wt %, or 55 wt %, or 60 wt %, or 65 wt %, or 70 wt %, or 80 wt %, or 90 wt %, or 95 wt % to 97 wt %, or 98 wt %, or 99 wt %, or 100 wt % ethylene, based on the total weight of the base ethylene-based polymer.
[0091] In an embodiment, the base ethylene-based polymer for the Si-g-PE has a density from 0.850 g/cc, or 0.860 g/cc, or 0.875 g/cc, or 0.890 g/cc to 0.900 g/cc, or 0.910 g/cc, or 0.915 g/cc, or 0.920 g/cc, or 0.930 g/cc, or 0.940 g/cc, or 0.950 g/cc, or 0.960 g/cc, or 0.965 g/cc.
[0092] In an embodiment, the base ethylene-based polymer for the Si-g-PE has a melt index (MI) from 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 70 g/10 min, or 80 g/10 min, or 90 g/10 min.
[0093] In an embodiment, the base ethylene-based polymer for the Si-g-PE is an ethylene/α-olefin copolymer. The α-olefin contains from 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.
[0094] In an embodiment, the ethylene-based copolymer is an ethylene/octene copolymer. When the ethylene-based copolymer is an ethylene/α-olefin copolymer, the Si-g-PE is a silane-grafted ethylene/α-olefin copolymer. Non-limiting examples of suitable ethylene/α-olefin copolymers useful as the base ethylene-based polymer for the Si-g-PE include the ENGAGE™ and INFUSE™ resins available from the Dow Chemical Company.
[0095] In an embodiment, the base ethylene-based polymer for the Si-g-PE is an ethylene plastomer or elastomer. “Ethylene plastomers/elastomers” are substantially linear, or linear, ethylene/α-olefin copolymers containing homogeneous short-chain branching distribution comprising units derived from ethylene and units derived from at least one C.sub.3-C.sub.10 α-olefin comonomer, or at least one C.sub.4-C.sub.8 α-olefin comonomer, or at least one C.sub.4-C.sub.8 α-olefin comonomer.
[0096] Ethylene plastomers/elastomers have a density from 0.870 g/cc, or 0.880 g/cc, or 0.890 g/cc to 0.900 g/cc, or 0.902 g/cc, or 0.904 g/cc, or 0.909 g/cc, or 0.910 g/cc, or 0.917 g/cc. Nonlimiting examples of ethylene plastomers/elastomers include AFFINITY™ plastomers and elastomers (available from The Dow Chemical Company), EXACT™ Plastomers (available from ExxonMobil Chemical), Tafmer™ (available from Mitsui), Nexlene™ (available from SK Chemicals Co.), and Lucene™ (available LG Chem Ltd.).
[0097] In an embodiment, the Si-g-PE is a silane-grafted ethylene/C.sub.4-C.sub.8 α-olefin copolymer. The silane-grafted ethylene/C.sub.4-C.sub.8 α-olefin copolymer consists of the hydrolyzable silane monomer, ethylene, and C.sub.4-C.sub.8 α-olefin comonomer. In other words, the silane-grafted ethylene/C.sub.4-C.sub.8 α-olefin copolymer contains the hydrolyzable silane monomer, ethylene, and C.sub.4-C.sub.8 α-olefin comonomer as the only monomeric units.
[0098] In an embodiment, the Si-g-PE is a silane-grafted ethylene/C.sub.4-C.sub.8 α-olefin copolymer. The silane-grafted ethylene/C.sub.4-C.sub.8 α-olefin copolymer consists of the hydrolyzable silane monomer, ethylene, and C.sub.4-C.sub.8 α-olefin comonomer. The silane-grafted ethylene/C.sub.4-C.sub.8 α-olefin copolymer has one, some, or all of the following properties: (a) a density from 0.850 g/cc, or 0.860 g/cc, or 0.875 g/cc, or 0.890 g/cc to 0.900 g/cc, or 0.910 g/cc, or 0.915 g/cc, or 0.920 g/cc, or 0.925 g/cc, or 0.930 g/cc, or 0.935 g/cc; and/or (b) a melt index from 0.1 g/10 min, or 0.5 g/10 min, or 1 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 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 90 g/10 min; and/or (c) a silane content of from 0.1 wt %, or 0.3 wt %, or 0.5 wt %, or 0.8 wt %, or 1.0 wt %, or 1.2 wt %, or 1.5 wt %, or 1.6 wt % to 1.8 wt %, or 2.0 wt %, or 2.3 wt %, or 2.5 wt %, or 3.0 wt %, or 3.5 wt %, or 4.0 wt %, or 4.5 wt %, or 5.0 wt %, based on the total weight of the silane-grafted ethylene/C.sub.4-C.sub.8 α-olefin copolymer.
[0099] The Si-g-PE may comprise two or more embodiments disclosed herein.
[0100] In an embodiment, the composition contains from 20 wt %, or 25 wt %, or 30 wt %, or 35 wt % to 36 wt %, or 40 wt %, or 45 wt %, or 50 wt %, or 55 wt %, or 60 wt %, or 65 wt %, or 70 wt %, or 75 wt %, or 80 wt % of the silane functionalized polyolefin, based on the total weight of the composition.
[0101] Blends of silane functionalized polyolefins may also be used, and the silane-functionalized polyolefin(s) may be diluted with one or more other polyolefins to the extent that the polyolefins are (i) miscible or compatible with one another, and (ii) the silane functionalized polyolefin(s) constitutes from 40 wt %, or 50 wt %, or 55 wt %, or 60 wt %, or 65 wt %, or 70 wt %, or 75 wt %, or 80 wt %, or 85 wt %, or 90 wt %, or 95 wt %, or 98 wt %, or 99 wt % to less than 100 wt % of the blend (based on the combined weight of the polyolefins, including the silane functionalized polyolefin).
[0102] In an embodiment, the composition includes the silane-functionalized polyolefin and a polyolefin that is an ethylene-based polyolefin. The ethylene-based polyolefin is different than the silane functionalized polyolefin because the ethylene-based polyolefin is not silane functionalized.
[0103] In an embodiment, the ethylene-based polyolefin is an ethylene plastomer or elastomer. In another embodiment, the ethylene-based polyolefin is an LDPE. In another embodiment, the ethylene-based polyolefin is an ethylene/α-olefin copolymer, or further a maleic-anhydride (MAH)-grafted ethylene/α-olefin copolymer. In an embodiment, the α-olefin is a C.sub.4-C.sub.8a-olefin. In another embodiment, the ethylene-based polyolefin is a copolymer of ethylene and maleic anhydride (such as ZeMacm E60 or ZeMac™ M603, available from Vertellus Holdings LLC), or a random ethylene copolymer with a comonomer that is classified as being a maleic anhydride equivalent for application purposes (such as FUSABOND™ M603, available from DuPont).
[0104] In an embodiment, the composition includes a polymeric blend containing, consisting essentially of, or consisting of the silane-functionalized polyolefin; optionally, one or more ethylene plastomer or elastomer; optionally, one or more MAH-grafted ethylene/C.sub.4-C.sub.8 α-olefin copolymer; and optionally, one or more LDPE. The silane functionalized polyolefin constitutes from 40 wt %, or 50 wt %, or 55 wt %, or 60 wt %, or 65 wt %, or 70 wt %, or 75 wt %, or 80 wt %, or 85 wt %, or 90 wt %, or 95 wt %, or 98 wt %, or 99 wt % to less than 100 wt % of the polymeric blend. In an embodiment, the polymeric blend contains, consists essentially of, or consists of (i) from 40 wt %, or 50 wt %, or 55 wt %, or 60 wt %, or 65 wt % to 70 wt %, or 75 wt %, or 80 wt % Si-g-PE; (ii) from 1 wt %, or 5 wt %, or 10 wt %, or 15 wt %, or 20 wt %, or 25 wt % to 30 wt %, or 35 wt %, or 40 wt %, or 45 wt %, or 50 wt %, or 55 wt % ethylene plastomer or elastomer (e.g., an ethylene/C.sub.4-C.sub.8 α-olefin copolymer); (iii) from 1 wt %, or 5 wt % to 10 wt %, or 15 wt %, or 20 wt %, or 25 wt %, or 30 wt %, or 35 wt %, or 40 wt %, or 45 wt %, or 50 wt %, or 55 wt % MAH-grafted ethylene/C.sub.4-C.sub.8 α-olefin copolymer; and (iv) from 0.1 wt %, or 0.5 wt %, or 0.8 wt % to 1.0 wt %, or 5 wt %, or 10 wt %, or 15 wt %, or 20 wt %, or 25 wt %, or 30 wt %, or 35 wt %, or 40 wt %, or 45 wt %, or 50 wt %, or 55 wt % LDPE, based on the total weight of the polymeric blend.
[0105] In an embodiment, the composition includes a polymeric blend containing, consisting essentially of, or consisting of (i) Si-g-PE, (ii) a first ethylene-based polymer, (iii) optionally, a second ethylene-based polymer, (iv) optionally, a third ethylene-based polymer, (v) optionally, a fourth ethylene-based polymer, and (vi) optionally, a fifth ethylene-based polymer. The ethylene-based polymers are different than the Si-g-PE because the ethylene-based polymers are not silane functionalized. Each ethylene-based polymer is compositionally, structurally, and/or physically different than the other ethylene-based polymers present in the composition. In other words, the first ethylene-based polymer is compositionally, structurally, and/or physically different than each of the second ethylene-based polymer, the third ethylene-based polymer, the fourth ethylene-based polymer, and the fifth ethylene-based polymer.
[0106] The silane functionalized polyolefin may comprise two or more embodiments disclosed herein.
[0107] B. Flame Retardant
[0108] The present composition includes a flame retardant. A “flame retardant” is a compound that inhibits or delays the spread of fire by suppressing combustion reactions. Nonlimiting examples of suitable flame retardants include halogen-free flame retardants, halogenated flame retardants, and combinations thereof.
[0109] In an embodiment, the composition includes a halogenated flame retardant. A “halogenated flame retardant” is a flame retardant compound that contains at least one halogen atom. A nonlimiting example of a suitable halogenated flame retardant is a brominated flame retardant such as decabromodiphenylethane (e.g., Saytex™ 8010, available from Albemarle Corporation), brominated polyphenyl ether (e.g., Emerald Innovation™ 1000, available from Great Lakes Solutions), and brominated styrene/butadiene block copolymer (e.g., Emerald Innovation™ 3000, available from LANXESS, which has a Mw greater than 100,000 g/mol). In an embodiment, an inorganic flame retardant synergist (such as antimony trioxide, zinc oxide, zinc stearate, and combinations thereof) is included in combination with the halogenated flame retardant.
[0110] In an embodiment, the composition includes a halogen-free flame retardant. Nonlimiting examples of suitable halogen-free flame retardants include metal hydrates, silica, glass powder, metal carbonate, antimony trioxide, and combinations thereof. In an embodiment, the halogen-free flame retardant is a metal hydrate. A nonlimiting example of a suitable metal hydrate is magnesium hydroxide.
[0111] In an embodiment, the composition contains from 20 wt %, or 25 wt %, or 30 wt %, or 35 wt %, or 40 wt % to 42 wt %, or 45 wt %, or 50 wt %, or 55 wt %, or 60 wt %, or 65 wt %, or 70 wt %, or 75 wt %, or 80 wt % of the halogen-free flame retardant, based on the total weight of the composition.
[0112] In an embodiment, the composition contains from 5 wt %, or 10 wt %, or 15 wt %, or 20 wt %, or 25 wt % to 30 wt %, or 35 wt %, or 40 wt %, or 45 wt %, or 50 wt %, or 55 wt %, or 60 wt %, or 65 wt %, or 70 wt % halogenated flame retardant, based on the total weight of the composition.
[0113] In an embodiment, the composition contains from 5 wt %, or 10 wt %, or 15 wt %, or 20 wt %, or 25 wt % to 30 wt %, or 35 wt %, or 40 wt %, or 45 wt %, or 50 wt %, or 55 wt %, or 60 wt %, or 65 wt %, or 70 wt % inorganic flame retardant synergist, based on the total weight of the composition.
[0114] In an embodiment, the weight ratio of halogenated flame retardant to inorganic flame retardant synergist is from 0.5:1 to 5:1, or from 0.7:1 to 4:1, or from 1:1 to 3:1.
[0115] The flame retardant may comprise two or more embodiments disclosed herein.
[0116] C. Hindered Amine Light Stabilizer (HALS)
[0117] The present composition includes a hindered amine light stabilizer (HALS) having a weight average molecular weight, Mw, greater than 5,000 Dalton (g/mol).
[0118] In an embodiment, the HALS has a Mw greater than 5,000 Dalton, or greater than 7,500 Dalton, or greater than 10,000 Dalton. In an embodiment, the HALS has a Mw from greater than 5,000 Dalton to 50,000 Dalton. In another embodiment, the HALS has a Mw from 5,500 Dalton, or 6,000 Dalton, or 7,000 Dalton, or 7,500 Dalton, or 8,000 Dalton, or 10,000 Dalton, or 11,000 Dalton, or 11,500 Dalton to 12,000 Dalton, or 13,000 Dalton, or 15,000 Dalton, or 20,000 Dalton, or 25,000 Dalton, or 30,000 Dalton, or 35,000 Dalton, or 40,000 Dalton, or 45,000 Dalton, or 50,000 Dalton. In another embodiment, the HALS has a Mw from 5,500 Dalton to 50,000 Dalton, or from 6,000 Dalton to 20,000 Dalton, or from 10,000 Dalton to 15,000 Dalton, or from 11,000 Dalton to 15,000 Dalton.
[0119] In an embodiment, the HALS with a Mw greater than 5,000 Dalton is a polymeric HALS. A “polymeric HALS” is a HALS with repeating monomeric units as shown in the following Structure (B):
##STR00002##
wherein
[0120] m is an integer from 3 to 20;
[0121] n is an integer from 2 to 12;
[0122] A.sup.1 and A.sup.2 each is independently selected from hydrogen, linear and branched C.sub.1-C.sub.12 alkyl groups, C.sub.3-C.sub.8 alkenyl groups, and C.sub.7-C.sub.19 aralkyl groups;
[0123] R.sup.1 and R.sup.2 each is independently selected from oxygen and a group of Structure (C):
##STR00003##
[0124] A.sup.3 is selected from hydrogen, linear and branched C.sub.1-C.sub.12 alkyl groups, C.sub.5-C.sub.12 cycloalkyl groups, and C.sub.7-C.sub.19 aralkyl groups;
[0125] X is a —(CH.sub.2).sub.p— group, wherein p is an integer from 2 to 12, with the proviso that p is a different integer than n;
[0126] Y is selected from C.sub.1-C.sub.18 alkyl groups, a group of Structure (D), and a group of Structure (E):
##STR00004##
[0127] Z is selected from an O-A.sup.4 group, a S-A.sup.4 group, and a group of Structure (F):
##STR00005##
and
[0128] A.sup.4 and A.sup.5 each is independently selected from hydrogen; linear and branched C.sub.1-C.sub.18 alkyl groups; C.sub.5-C.sub.12 cycloalkyl groups; C.sub.7-C.sub.12 aralkyl groups; C.sub.6-C.sub.12 aryl groups; or may form, together with the nitrogen atom to which they are linked, a C.sub.5-C.sub.7 heterocycle; and a piperidine group of Structure (G):
##STR00006##
[0129] In Structure (B), m refers to the number of repeating units of the piperidine compound.
[0130] In an embodiment, the HALS has the Structure (B), wherein: m is an integer from 3 to 20; n is an integer from 3 to 12; A.sup.1 and A.sup.2 each is hydrogen; R.sup.1 and R.sup.2 each is a group of Structure (C); A.sup.3 is a linear C.sub.4 alkyl group; X is a —(CH.sub.2).sub.2— group; Y is a group of Structure (D); Z is a group of Structure (F); and A.sup.4 and A.sup.5 each is a piperidine group of Structure (G).
[0131] In an embodiment, the HALS with a Mw greater than 5,000 Dalton has the following Structure (H):
##STR00007##
wherein m is an integer from 3 to 20.
[0132] A nonlimiting example of a suitable HALS having the Structure (H) is UVASORB™ HA10 (CAS 136504-96-6), available from 3V Sigma USA. UVASORB™ HA10 has a Mw of 11,600 Dalton.
[0133] In an embodiment, the HALS with a Mw greater than 5,000 Dalton is a poly(styryl-co-styryl isocyanate) having a HALS functional group bonded to the terminal isocyanate chain end, as described in Singh, R. P. et al, Journal of Applied Polymer Science, Vol. 90, 1126-1138 (2003), the entire contents of which are herein incorporated by reference.
[0134] In an embodiment, the composition contains from 0.10 wt %, or 0.15 wt %, or 0.20 wt % to 0.25 wt %, or 0.30 wt %, or 0.35 wt %, or 0.40 wt %, or 0.45 wt %, or 0.50 wt % HALS having a Mw greater than 5,000 Dalton, based on the total weight of the composition.
[0135] The HALS may comprise two or more embodiments disclosed herein.
[0136] D. Additives
[0137] The present composition may include one or more additives. Nonlimiting examples of suitable additives include antioxidants, colorants, corrosion inhibitors, lubricants, silanol condensation catalysts, ultra violet (UV) absorbers or stabilizers, anti-blocking agents, coupling agents, compatibilizers, plasticizers, fillers, processing aids, moisture scavengers, scorch retardants, metal deactivators, siloxanes, and combinations thereof.
[0138] In an embodiment, the composition includes an antioxidant. “Antioxidant” refers to types or classes of chemical compounds that are capable of being used to minimize the oxidation that can occur during the processing of polymers. Nonlimiting examples of suitable antioxidants include high molecular weight hindered phenols and multifunctional phenols such as sulfur and phosphorous-containing phenol. A nonlimiting example of a suitable hindered phenol is pentaerythritol tetrakis(3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate), commercially available as Irganox© 1010 from BASF. In an embodiment, the composition contains from 0 wt %, or 0.001 wt %, or 0.01 wt %, or 0.02 wt %, or 0.05 wt %, or 0.1 wt %, or 0.2 wt %, or 0.3 wt % to 0.4 wt %, or 0.5 wt %, or 0.6 wt %, or 0.7 wt %, or 0.8 wt %, or 1.0 wt %, or 2.0 wt %, or 2.5 wt %, or 3.0 wt % antioxidant, based on total weight of the composition.
[0139] In an embodiment, the composition includes silanol condensation catalyst, such as Lewis and Brçnsted acids and bases. A “silanol condensation catalyst” promotes crosslinking of the silane functionalized polyolefin. Lewis acids are chemical species that can accept an electron pair from a Lewis base. Lewis bases are chemical species that can donate an electron pair to a Lewis acid.
[0140] Nonlimiting examples of suitable Lewis acids include the tin carboxylates such as dibutyl tin dilaurate (DBTDL), and various other organo-metal compounds such as lead naphthenate, zinc caprylate and cobalt naphthenate. Nonlimiting examples of suitable Lewis bases include the primary, secondary and tertiary amines. These catalysts are typically used in moisture cure applications. In an embodiment, the composition includes from 0 wt %, or 0.001 wt %, or 0.005 wt %, or 0.01 wt %, or 0.02 wt %, or 0.03 wt % to 0.05 wt %, or 0.1 wt %, or 0.2 wt %, or 0.5 wt %, or 1.0 wt % silanol condensation catalyst, based on the total weight of the composition. During the MONOSIL™ process, the silanol condensation catalyst is typically added to the reaction-extruder so that it is present during the grafting reaction of silane to the polyolefin backbone to form the in situ Si-g-PO. As such, the silane functionalized polyolefin may experience some coupling (light crosslinking) before it leaves the extruder with the completion of the crosslinking after it has left the extruder, typically upon exposure to moisture (e.g., a sauna bath or a cooling bath) and/or the humidity present in the environment in which it is stored, transported or used.
[0141] In an embodiment, the silanol condensation catalyst is included in a catalyst masterbatch blend, and the catalyst masterbatch is included in the composition. Nonlimiting examples of suitable catalyst masterbatches include those sold under the trade name SI-LINK™ from The Dow Chemical Company, including SI-LINK™ DFDA-5481 Natural. SI-LINK™ DFDA-5481 Natural is a catalyst masterbatch 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. In an embodiment, the composition contains from 0 wt %, or 0.001 wt %, or 0.01 wt %, or 0.1 wt %, or 0.3 wt %, or 0.5 wt %, or 1.0 wt %, or 2.0 wt %, or 3.0 wt %, or 4.0 wt % to 5.0 wt %, or 6.0 wt %, or 7.0 wt %, or 8.0 wt %, or 9.0 wt %, or 10.0 wt % silanol condensation catalyst or catalyst masterbatch, based on total weight of the composition.
[0142] In an embodiment, the composition includes an ultraviolet (UV) absorber or stabilizer that is compositionally and/or structurally distinct from the HALS having an Mw greater than 5,000 Dalton. A nonlimiting example of a suitable UV stabilizer is a HALS having a Mw less than 5,000 Dalton, such as 1,3,5-Triazine-2,4,6-triamine, N,N-1,2-ethanediylbisN-3-4,6-bisbutyl(1,2,2,6,6-pentamethyl-4-piperidinyl)amino-1,3,5-triazin-2-ylaminopropyl-N,N-dibutyl-N,N-bis(1,2,2,6,6-pentamethyl-4-piperidinyl)-1,5,8,12-tetrakis[4,6-bis(n-butyl-n-1,2,2,6,6-pentamethyl-4-piperidylamino)-1,3,5-triazin-2-yl]-1,5,8,12-tetraazadodecane, which is commercially available as SABO™ STAB UV-119 from SABO S.p.A. of Levate, Italy. In an embodiment, the composition contains from 0 wt %, or 0.001 wt %, or 0.002 wt %, or 0.005 wt %, or 0.006 wt % to 0.007 wt %, or 0.008 wt %, or 0.009 wt %, or 0.01 wt %, or 0.1 wt %, or 0.2 wt %, or 0.3 wt %, or 0.4 wt %, or 0.5 wt %, or 1.0 wt %, or 2.0 wt %, or 2.5 wt %, or 3.0 wt % UV absorber or stabilizer, based on total weight of the composition.
[0143] In an embodiment, the composition excludes HALS having a Mw less than 5,000 Dalton.
[0144] In an embodiment, the composition includes a metal deactivator. Metal deactivators suppress the catalytic action of metal surfaces and traces of metallic minerals. Metal deactivators convert the traces of metal 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). The metal deactivator is present in an amount from 0 wt %, or greater than 0 wt %, or 0.01 wt %, or 0.02 wt %, or 0.03 wt %, or 0.04 wt % to 0.05 wt %, or 0.1 wt %, or 0.5 wt %, or 1 wt %, or 2 wt %, or 3 wt %, or 5 wt %, or 8 wt %, or 10 wt %, based on the total weight of the composition.
[0145] In an embodiment, the composition includes a filler. Nonlimiting examples of suitable fillers include zinc oxide, zinc borate, zinc molybdate, zinc sulfide, carbon black, organo-clay, and combinations thereof. The filler may or may not have flame retardant properties. In an embodiment, the filler is coated with a material (such as stearic acid) that will prevent or retard any tendency that the filler might otherwise have to interfere with the silane cure reaction. In an embodiment, the composition contains from 0 wt %, or 0.01 wt %, or 0.02 wt %, or 0.05 wt %, or 0.1 wt %, or 0.2 wt %, or 0.4 wt % to 0.5 wt %, or 0.6 wt %, or 0.8 wt %, or 1.0 wt %, or 2.0 wt %, or 2.5 wt %, or 3.0 wt %, or 5.0 wt %, or 8.0 wt %, or 10.0 wt %, or 20 wt % filler, based on total weight of the composition.
[0146] In an embodiment, the composition includes a processing aid. Nonlimiting examples of suitable processing aids include oils, organic acids (such as stearic acid), and metal salts of organic acids (such as zinc stearate). In an embodiment, the composition contains from 0 wt %, or 0.01 wt %, or 0.02 wt %, or 0.05 wt %, or 0.1 wt %, or 0.2 wt %, or 0.3 wt %, or 0.4 wt % to 0.5 wt %, or 0.6 wt %, or 0.7 wt %, or 1.0 wt %, or 2.0 wt %, or 2.5 wt %, or 3.0 wt % processing aid, based on total weight of the composition.
[0147] In an embodiment, the composition includes a moisture scavenger. Moisture scavengers remove or deactivate unwanted water in the composition to prevent unwanted (premature) crosslinking and other water-initiated reactions in the composition during storage or at extrusion conditions. Non-limiting examples of moisture scavengers include organic compounds selected from ortho esters, acetals, ketals or silanes such as alkoxysilanes. In an embodiment, the moisture scavenger is an alkoxy silane (e.g., hexadecyltrimethoxysilane, octyltrimethoxysilane, or octyltriethoxysilane). The alkoxy silane moisture scavenger is not grafted to a polyolefin or copolymerized with an olefin such as ethylene. The moisture scavenger is present in an amount from 0 wt %, or greater than 0 wt %, or 0.01 wt %, or 0.02 wt %, or 0.03 wt %, or 0.04 wt %, or 0.05 wt %, or 0.1 wt % to 0.2 wt %, or 0.3 wt %, or 0.5 wt %, or 0.75 wt %, or 1.0 wt %, or 1.5 wt %, or 2.0 wt %, or 3.0 wt %, based on the total weight of the composition.
[0148] In an embodiment, the composition includes a siloxane. A nonlimiting example of a suitable siloxane is a polydimethylsiloxane (PDMS). A nonlimiting example of a suitable PDMS is dimethylvinylsilyl terminated polydimethylsiloxane. In an embodiment, PDMS is included in a PDMS masterbatch blend, and the PDMS masterbatch is included in the composition. A nonlimiting example of a suitable PDMS masterbatch is MB50-002 Masterbatch, available from Dow Corning. MB50-002 Masterbatch includes 50 wt % dimethylvinylsilyl terminated PDMS dispersed in LDPE, based on the total weight of the masterbatch. In an embodiment, the composition contains from 0.2 wt %, or 0.5 wt %, or 0.8 wt % to 1.0 wt %, or 1.5 wt %, or 2.0 wt %, or 2.5 wt %, or 3.0 wt %, or 5.0 wt % siloxane, based on the total weight of the composition. In another embodiment, the composition contains from 0.5 wt %, or 1.0 wt %, or 1.5 wt %, or 1.8 wt % to 2.0 wt %, or 2.5 wt %, or 3.0 wt %, or 5.0 wt % PDMS masterbatch, based on the total weight of the composition.
[0149] In an embodiment, the composition includes an additive selected from a silanol condensation catalyst (which may be included in a catalyst masterbatch blend), a moisture scavenger (e.g., hexadecyltrimethoxysilane), an antioxidant (e.g., pentaerythritol tetrakis(3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate)), a metal deactivator (e.g., OABH), a siloxane (e.g., a PDMS, which may be included in a PDMS masterbatch blend), and combinations thereof.
[0150] In an embodiment, the composition contains from 0 wt %, or greater than 0 wt %, or 0.001 wt %, or 0.002 wt %, or 0.005 wt %, or 0.006 wt % to 0.007 wt %, or 0.008 wt %, or 0.009 wt %, or 0.01 wt %, or 0.1 wt %, or 0.2 wt %, or 0.3 wt %, or 0.4 wt %, or 0.5 wt %, or 1.0 wt %, or 2.0 wt %, or 2.5 wt %, or 3.0 wt %, or 4.0 wt %, or 5.0 wt % to 6.0 wt %, or 7.0 wt %, or 8.0 wt %, or 9.0 wt %, or 10.0 wt %, or 15.0 wt %, or 20.0 wt % additive, based on the total weight of the composition.
[0151] The additive may comprise two or more embodiments disclosed herein.
[0152] E. Composition
[0153] In an embodiment, the composition includes: (A) a silane functionalized polyolefin (e.g., a silane functionalized polyethylene); (B) a halogen-free flame retardant (e.g., magnesium hydroxide); (C) a hindered amine light stabilizer (HALS) having a Mw greater than 5,000 Dalton; (D) optional additive.
[0154] The silane functionalized polyolefin; halogen-free flame retardant; HALS having a Mw greater than 5,000 Dalton; and optional additive may be any respective silane functionalized polyolefin; halogen-free flame retardant; HALS having a Mw greater than 5,000 Dalton; and optional additive disclosed herein.
[0155] In an embodiment, the composition contains, consists essentially of, or consists of: (A) from 20 wt %, or 25 wt %, or 30 wt %, or 35 wt % to 36 wt %, or 40 wt %, or 45 wt %, or 50 wt %, or 55 wt %, or 60 wt %, or 65 wt %, or 70 wt %, or 75 wt %, or 80 wt % silane functionalized polyolefin; (b) from 20 wt %, or 25 wt %, or 30 wt %, or 35 wt %, or 40 wt % to 42 wt %, or 45 wt %, or 50 wt %, or 55 wt %, or 60 wt %, or 65 wt %, or 70 wt %, or 75 wt %, or 80 wt % halogen-free flame retardant; (c) from 0.10 wt %, or 0.15 wt %, or 0.20 wt % to 0.25 wt %, or 0.30 wt %, or 0.35 wt %, or 0.40 wt %, or 0.45 wt %, or 0.50 wt % HALS having a Mw greater than 5,000 Dalton; and (d) from 0 wt %, or greater than 0 wt %, or 0.001 wt %, or 0.002 wt %, or 0.005 wt %, or 0.006 wt % to 0.007 wt %, or 0.008 wt %, or 0.009 wt %, or 0.01 wt %, or 0.1 wt %, or 0.2 wt %, or 0.3 wt %, or 0.4 wt %, or 0.5 wt %, or 1.0 wt %, or 2.0 wt %, or 2.5 wt %, or 3.0 wt %, or 4.0 wt %, or 5.0 wt % to 6.0 wt %, or 7.0 wt %, or 8.0 wt %, or 10.0 wt %, or 15.0 wt %, or 20.0 wt % additive.
[0156] It is understood that the sum of the components in each of the foregoing compositions yields 100 weight percent (wt %).
[0157] In an embodiment, the composition yields a wet insulation resistance (IR) greater than 500 megaohm/3.048 meter (Mohm/3.048 m), or greater than 600 Mohm/3.048 m, or greater than 700 Mohm/3.048 mat 90° C. from 6 hours to 7 weeks, or from 6 hours to 9 weeks, or from 6 hours to 12 weeks, or from 6 hours to 24 weeks, or from 6 hours to 36 weeks.
[0158] In an embodiment, the composition yields a wet insulation resistance (IR) greater than 800 Mohm/3.048 m, or greater than 1,000 Mohm/3.048 m, or greater than 1,300 Mohm/3.048 m, or greater than 1,500 Mohm/3.048 mat 90° C. from 6 hours to 7 weeks, or from 6 hours to 9 weeks, or from 6 hours to 12 weeks, or from 6 hours to 24 weeks, or from 6 hours to 36 weeks. In another embodiment, the composition yields a wet IR from 800 Mohm/3.048 m, or 1,000 Mohm/3.048 m, or 1,300 Mohm/3.048 m, or 1,500 Mohm/3.048 m to 2,000 Mohm/3.048 m, or 3.00 Mohm/3.048 m, or 4,000 Mohm/3.048 m, or 5,000 Mohm/3.048 m, or 10,000 Mohm/3.048 m, or 15,000 Mohm/3.048 m, or 20,000 Mohm/3.048 m, or 30,000 Mohm/3.048 m, or 40,000 Mohm/3.048 m, or 50,000 Mohm/3.048 m at 90° C. from 6 hours to 7 weeks, or from 6 hours to 9 weeks, or from 6 hours to 12 weeks, or from 6 hours to 24 weeks, or from 6 hours to 36 weeks.
[0159] In an embodiment, the composition yields a wet IR ratio from 0.4, or 0.5, or 0.6, or 0.7, or 0.8, or 0.9, or 1.0 to 1.1, or 1.5, or 2.0, or 3.0, or 5.0, or 10, or 15, or 20.
[0160] In an embodiment, the composition has a tensile stress at break from 500 psi (3.45 megaPascal (MPa)), or 700 psi (4.83 MPa), or 1,000 psi (6.90 MPa), or 1,300 psi (8.96 MPa), or 1,500 psi (10.34 MPa), or 2,000 psi (13.79 MPa), or 2,100 psi (14.48 MPa) to 2,200 psi (15.17 MPa), or 2,500 psi (17.24 MPa), or 3,000 psi (20.68 MPa), or 4,000 psi (27.58 MPa), or 5,000 psi (34.47 MPa).
[0161] In an embodiment, the composition has a tensile elongation at break from 100%, or 125%, or 150%, or 200%, or 250%, or 300%, or 400%, or 430% to 440%, or 450%, or 500%, or 600%, or 700%, or 800%.
[0162] In an embodiment, the composition yields a crush resistance from 800 lb-f (362.81 kg-f), or 1,000 lb-f (453.51 kg-f), or 1,200 lb-f (544.22 kg-f), or 1,500 lb-f (680.27 kg-f), or 1,520 lb-f (689.34 kg-f) to 1,550 lb-f (702.95 kg-f), or 1,600 lb-f (725.62 kg-f), or 2,000 lb-f (907.03 kg-f), or 2,500 lb-f (1133.79 kg-f), or 3,000 lb-f (1360.54 kg-f).
[0163] In an embodiment, the composition has a hot creep from 0%, or 1%, or 2%, or 5%, or 10%, or 15%, or 20%, or 25%, or 30%, or 35% to 40%, or 50%, or 60%, or 70%, or 75%, or 80%, or 90%, or 100%, or 150%, or 170% at 0.2 MPa and 150° C.
[0164] In an embodiment, the composition yields a retained dielectric strength (retained ACBD) after glancing impact from 20%, or 25%, or 30%, or 35%, or 40%, or 45%, or 50%, or 55%, or 60%, or 65%, or 70%, or 75%, or 80%, or 85%, or 90%, or 95% to 100%; or from 20% to 100%, or from 75% to 100%.
[0165] In an embodiment, the composition is halogen-free.
[0166] In an embodiment, the composition contains, consists essentially of, or consists of: (A) from 20 wt %, or 25 wt %, or 30 wt %, or 35 wt % to 36 wt %, or 40 wt %, or 45 wt %, or 50 wt %, or 55 wt %, or 60 wt %, or 65 wt %, or 70 wt %, or 75 wt %, or 80 wt % silane functionalized polyolefin (e.g., a Si-g-PE); (B) from 20 wt %, or 25 wt %, or 30 wt %, or 35 wt %, or 40 wt % to 42 wt %, or 45 wt %, or 50 wt %, or 55 wt %, or 60 wt %, or 65 wt %, or 70 wt %, or 75 wt %, or 80 wt % halogen-free flame retardant (e.g., a metal hydroxide); (C) from 0.10 wt %, or 0.15 wt %, or 0.20 wt % to 0.25 wt %, or 0.30 wt %, or 0.35 wt %, or 0.40 wt %, or 0.45 wt %, or 0.50 wt % HALS having a Mw greater than 5,000 Dalton (e.g., of Structure (H)); and (D) from 0 wt %, or greater than 0 wt %, or 0.001 wt %, or 0.002 wt %, or 0.005 wt %, or 0.006 wt % to 0.007 wt %, or 0.008 wt %, or 0.009 wt %, or 0.01 wt %, or 0.1 wt %, or 0.2 wt %, or 0.3 wt %, or 0.4 wt %, or 0.5 wt %, or 1.0 wt %, or 2.0 wt %, or 2.5 wt %, or 3.0 wt %, or 4.0 wt %, or 5.0 wt % to 6.0 wt %, or 7.0 wt %, or 8.0 wt %, or 9.0 wt %, or 10.0 wt %, or 15.0 wt %, or 20.0 wt % additive; and the composition or coated conductor has one, some, or all of the following properties: (i) a wet IR from 500 Mohm/3.048 m, or 800 Mohm/3.048 m, or 1,000 Mohm/3.048 m, or 1,500 Mohm/3.048 m to 5,000 Mohm/3.048 m, or 10,000 Mohm/3.048 m, or 15,000 Mohm/3.048 m, or 20,000 Mohm/3.048 m, or 30,000 Mohm/3.048 m, or 50,000 Mohm/3.048 m at 90° C. from 6 hours to 24 weeks; and/or (ii) a wet IR ratio from 0.4, or 0.5, or 0.6, or 0.7, or 0.8, or 0.9, or 1.0 to 1.1, or 1.5, or 2.0, or 3.0, or 5.0; and/or (iii) a tensile stress at break from 1,000 psi (6.90 MPa), or 2,000 psi (13.79 MPa), or 2,100 psi (14.48 MPa) to 2,200 psi (15.17 MPa), or 2,500 psi (17.24 MPa), or 3,000 psi (20.68 MPa), or 4,000 psi (27.58 MPa), or 5,000 psi (34.47 MPa); and/or (iv) a tensile elongation at break from 100%, or 300%, or 400%, or 430% to 440%, or 450%, or 500%, or 600%, or 700%, or 800%; and/or (v) a crush resistance from 1,000 lb-f (453.51 kg-f), or 1,500 lb-f (680.27 kg-f), or 1,520 lb-f (689.34 kg-f) to 1,550 lb-f (702.95 kg-f), or 1,600 lb-f (725.62 kg-f), or 2,000 lb-f (907.03 kg-f), or 2,500 lb-f (1133.79 kg-f), or 3,000 lb-f (1360.54 kg-f); and/or (vi) a hot creep from 10%, or 15%, or 20%, or 25%, or 30%, or 35% to 40%, or 50%, or 60%, or 70%, or 75%, or 80% at 0.2 MPa and 150° C.; and/or (vii) a retained ACBD after glancing impact from 20%, or 25%, or 30%, or 35%, or 40%, or 45%, or 50%, or 55%, or 60%, or 65%, or 70%, or 75%, or 80%, or 85%, or 90%, or 95% to 100%; and/or (viil) the composition is halogen-free.
[0167] In an embodiment, the composition contains, consists essentially of, or consists of: (A) from 20 wt %, or 25 wt %, or 30 wt %, or 35 wt % to 36 wt %, or 40 wt %, or 45 wt %, or 50 wt %, or 55 wt %, or 60 wt %, or 65 wt %, or 70 wt %, or 75 wt %, or 90 wt % silane functionalized polyolefin (e.g., a Si-g-PE); (B) from 5 wt %, or 10 wt %, or 15 wt %, or 20 wt %, or 25 wt % to 30 wt %, or 35 wt %, or 40 wt %, or 45 wt %, or 50 wt %, or 55 wt %, or 60 wt %, or 65 wt %, or 70 wt % halogenated flame retardant; (C) from 5 wt %, or 10 wt %, or 15 wt %, or 20 wt %, or 25 wt % to 30 wt %, or 35 wt %, or 40 wt %, or 45 wt %, or 50 wt %, or 55 wt %, or 60 wt %, or 65 wt %, or 70 wt % inorganic flame retardant synergist; (D) from 0.10 wt %, or 0.15 wt %, or 0.20 wt % to 0.25 wt %, or 0.30 wt %, or 0.35 wt %, or 0.40 wt %, or 0.45 wt %, or 0.50 wt % HALS having a Mw greater than 5,000 Dalton (e.g., of Structure (H)); and (E) from 0 wt %, or greater than 0 wt %, or 0.001 wt %, or 0.002 wt %, or 0.005 wt %, or 0.006 wt % to 0.007 wt %, or 0.008 wt %, or 0.009 wt %, or 0.01 wt %, or 0.1 wt %, or 0.2 wt %, or 0.3 wt %, or 0.4 wt %, or 0.5 wt %, or 1.0 wt %, or 2.0 wt %, or 2.5 wt %, or 3.0 wt %, or 4.0 wt %, or 5.0 wt % to 6.0 wt %, or 7.0 wt %, or 8.0 wt %, or 9.0 wt %, or 10.0 wt %, or 15.0 wt %, or 20.0 wt % additive; and the composition or coated conductor has one, some, or all of the following properties: (i) a wet IR from 500 Mohm/3.048 meter, or 800 Mohm/3.048 meter, or 1,000 Mohm/3.048 meter, or 1,500 Mohm/3.048 meter to 5,000 Mohm/3.048 meter, or 10,000 Mohm/3.048 meter, or 15,000 Mohm/3.048 meter, or 20,000 Mohm/3.048 meter, or 30,000 Mohm/3.048 meter, or 50,000 Mohm/3.048 meter at 90° C. from 6 hours to 24 weeks; and/or (ii) a wet IR ratio from 0.4, or 0.5, or 0.6, or 0.7, or 0.8, or 0.9, or 1.0 to 1.1, or 1.5, or 2.0, or 3.0, or 5.0; and/or (iii) a tensile stress at break from 1,000 psi (6.90 MPa), or 2,000 psi (13.79 MPa), or 2,100 psi (14.48 MPa) to 2,200 psi (15.17 MPa), or 2,500 psi (17.24 MPa), or 3,000 psi (20.68 MPa), or 4,000 psi (27.58 MPa), or 5,000 psi (34.47 MPa); and/or (iv) a tensile elongation at break from 100%, or 300%, or 400%, or 430% to 440%, or 450%, or 500%, or 600%, or 700%, or 800%; and/or (v) a crush resistance from 1,000 lb-f (453.51 kg-f), or 1,500 lb-f (680.27 kg-f), or 1,520 lb-f (689.34 kg-f) to 1,550 lb-f (702.95 kg-f), or 1,600 lb-f (725.62 kg-f), or 2,000 lb-f (907.03 kg-f), or 2,500 lb-f (1133.79 kg-f), or 3,000 lb-f (1360.54 kg-f); and/or (vi) a hot creep from 10%, or 15%, or 20%, or 25%, or 30%, or 35% to 40%, or 50%, or 60%, or 70%, or 75%, or 80% at 0.2 MPa and 150° C.; and/or (vii) a retained ACBD after glancing impact from 20%, or 25%, or 30%, or 35%, or 40%, or 45%, or 50%, or 55%, or 60%, or 65%, or 70%, or 75%, or 80%, or 85%, or 90%, or 95% to 100%.
[0168] In an embodiment, the composition is moisture-curable. In another embodiment, the composition is crosslinked.
[0169] The composition may comprise two or more embodiments disclosed herein.
[0170] F. Coated Conductor
[0171] The present disclosure also provides a coated conductor. The coated conductor includes a conductor and a coating on the conductor, the coating including a composition. The composition includes a silane functionalized polyolefin; a flame retardant (e.g., a halogen-free flame retardant); a HALS having a Mw greater than 5,000 Dalton; and optional additive.
[0172] The composition may be any composition disclosed herein. The silane functionalized polyolefin, flame retardant, HALS having a Mw greater than 5,000 Dalton, and optional additive may be any respective silane functionalized polyolefin, flame retardant, HALS having a Mw greater than 5,000 Dalton, and optional additive disclosed herein.
[0173] In an embodiment, the coating is an insulation sheath for a conductor. In another embodiment, the coating is a jacket for a conductor.
[0174] The process for producing a coated conductor includes heating the present composition to at least the melting temperature of the silane functionalized polyolefin, and then extruding the polymeric melt blend onto the conductor. The term “onto” includes direct contact or indirect contact between the polymeric melt blend and the conductor. The polymeric melt blend is in an extrudable state.
[0175] The coating is located on the conductor. The coating may be one or more inner layers such as an insulating layer. The coating may wholly or partially cover or otherwise surround or encase the conductor. The coating may be the sole component surrounding the conductor. When the coating is the sole component surrounding the conductor, the coating may serve as a jacket and/or an insulation. In an embodiment, the coating is the outermost layer on the coated conductor. Alternatively, the coating may be one layer of a multilayer jacket or sheath encasing the metal conductor. In an embodiment, the coating directly contacts the conductor. In another embodiment, the coating directly contacts an insulation layer surrounding the conductor.
[0176] In an embodiment, the coating directly contacts the conductor. The term “directly contacts,” as used herein, is a coating configuration whereby the coating is located immediately adjacent to the conductor, the coating touches the conductor, and no intervening layers, no intervening coatings, and/or no intervening structures, are present between the coating and the conductor.
[0177] In another embodiment, the coating indirectly contacts the conductor. The term “indirectly contacts,” as used herein, is a coating configuration whereby an intervening layer, an intervening coating, or an intervening structure, is present between the coating and the conductor. Nonlimiting examples of suitable intervening layers, intervening coatings, and intervening structures include insulation layers, moisture barrier layers, buffer tubes, and combinations thereof. Nonlimiting examples of suitable insulation layers include foamed insulation layers, thermoplastic insulation layers, crosslinked insulation layers, and combinations thereof.
[0178] The coating is crosslinked. In an embodiment, crosslinking of the present composition begins in the extruder, but only to a minimal extent. In another embodiment, crosslinking is delayed until the composition is extruded upon the conductor. Crosslinking of the present composition can be initiated and/or accelerated through exposure to humid environment (e.g., ambient conditions or cure in a sauna or water bath), and/or the application of heat (including when peroxides are used for crosslinking) or radiation. In an embodiment, after extrusion, the coated conductor is conditioned at humid conditions to cause crosslinking of the polymer layers and yield suitably low hot creep values (i.e., from 10% to 80%, or from 5% to 175%, measured at 150° C. or 200° C.).
[0179] In an embodiment, the coated conductor passes the horizontal burn test. To pass the horizontal burn test, the coated conductor must have a total char length of less than 100 mm and cotton placed underneath must not be ignited.
[0180] In an embodiment, the coated conductor has a wet IR greater than greater than 500 Mohm/3.048 m, or greater than 600 Mohm/3.048 m, or greater than 700 Mohm/3.048 m at 90° C. from 6 hours to 7 weeks, or from 6 hours to 9 weeks, or from 6 hours to 12 weeks, or from 6 hours to 24 weeks, or from 6 hours to 36 weeks.
[0181] In an embodiment, the coated conductor has a wet IR greater than greater than 800 Mohm/3.048 m, or greater than 1,000 Mohm/3.048 m, or greater than 1,300 Mohm/3.048 m, or greater than 1,500 Mohm/3.048 m at 90° C. from 6 hours to 7 weeks, or from 6 hours to 9 weeks, or from 6 hours to 12 weeks, or from 6 hours to 24 weeks, or from 6 hours to 36 weeks. In another embodiment, the coated conductor has a wet IR from 800 Mohm/3.048 m, or 1,000 Mohm/3.048 m, or 1,300 Mohm/3.048 m, or 1,500 Mohm/3.048 m to 2,000 Mohm/3.048 m, or 3.00 Mohm/3.048 m, or 4,000 Mohm/3.048 m, or 5,000 Mohm/3.048 m, or 10,000 Mohm/3.048 m, or 15,000 Mohm/3.048 m, or 20,000 Mohm/3.048 m, or 30,000 Mohm/3.048 m, or 40,000 Mohm/3.048 m, or 50,000 Mohm/3.048 m at 90° C. from 6 hours to 7 weeks, or from 6 hours to 9 weeks, or from 6 hours to 12 weeks, or from 6 hours to 24 weeks, or from 6 hours to 36 weeks.
[0182] In an embodiment, the coated conductor has a wet IR ratio from 0.4, or 0.5, or 0.6, or 0.7, or 0.8, or 0.9, or 1.0 to 1.1, or 1.5, or 2.0, or 3.0, or 5.0, or 10, or 15, or 20.
[0183] In an embodiment, the coated conductor is halogen-free.
[0184] In an embodiment, the coated conductor has a retained ACBD after glancing impact greater than 20%, or greater than 75%, or from 20%, or 25%, or 30%, or 35%, or 40%, or 45%, or 50%, or 55%, or 60%, or 65%, or 70%, or 75%, or 80%, or 85%, or 90%, or 95% to 100%; and the composition has one, some, or all, of the following properties: (i) a retained tensile strength after 7 days in an oven at 121° C. greater than 94%, or from 94%, or 94.5% to 100%; and/or (ii) a retained tensile elongation after 7 days in an oven at 121° C. greater than 87%, or from 87%, or 88% to 100%; and/or (iii) a retained tensile strength after 30 days in a weatherometer greater than 95%, or greater than 97%, or greater than 99%; and/or (iv) a retained tensile elongation after 30 days in a weatherometer greater than 81%, or from 81%, or 82% to 100%.
[0185] The coated conductor includes a conductor and a coating on the conductor, the coating including a composition. In an embodiment, the composition contains, consists essentially of, or consists of: (A) from 20 wt %, or 25 wt %, or 30 wt %, or 35 wt % to 36 wt %, or 40 wt %, or 45 wt %, or 50 wt %, or 55 wt %, or 60 wt %, or 65 wt %, or 70 wt %, or 75 wt %, or 80 wt % of the silane functionalized polyolefin (e.g., a Si-g-PE); (B) from 20 wt %, or 25 wt %, or 30 wt %, or 35 wt %, or 40 wt % to 42 wt %, or 45 wt %, or 50 wt %, or 55 wt %, or 60 wt %, or 65 wt %, or 70 wt %, or 75 wt %, or 80 wt % of the halogen-free flame retardant (e.g., a metal hydroxide); (C) from 0.10 wt %, or 0.15 wt %, or 0.20 wt % to 0.25 wt %, or 0.30 wt %, or 0.35 wt %, or 0.40 wt %, or 0.45 wt %, or 0.50 wt % HALS having a Mw greater than 5,000 Dalton (e.g., a HALS of Structure (H)); and (D) from 0 wt %, or greater than 0 wt %, or 0.001 wt %, or 0.005 wt %, to 0.007 wt %, or 0.009 wt %, or 0.01 wt %, or 0.1 wt %, or 0.2 wt %, or 0.5 wt %, or 1.0 wt %, or 2.0 wt %, or 2.5 wt %, or 3.0 wt %, or 4.0 wt %, or 5.0 wt % to 6.0 wt %, or 7.0 wt %, or 8.0 wt %, or 10.0 wt %, or 15.0 wt %, or 20.0 wt % additive; and the coated conductor has one, some, or all of the following properties: (i) a wet IR from 800 Mohm/3.048 m, or 1,000 Mohm/3.048 m, or 1,500 Mohm/3.048 m to 5,000 Mohm/3.048 m, or 10,000 Mohm/3.048 m, or 15,000 Mohm/3.048 m, or 20,000 Mohm/3.048 m, or 30,000 Mohm/3.048 m, or 40,000 Mohm/3.048 m, or 50,000 Mohm/3.048 m at 90° C. from 0 to 24 weeks; and/or (ii) a wet IR ratio from 0.4, or 0.5, or 0.6, or 0.7, or 0.8, or 0.9, or 1.0 to 1.1, or 1.5, or 2.0, or 3.0, or 5.0; (iii) a crush resistance from 1,000 lb-f (453.51 kg-f), or 1,500 lb-f (680.27 kg-f), or 1,520 lb-f (689.34 kg-f) to 1,550 lb-f (702.95 kg-f), or 1,600 lb-f (725.62 kg-f), or 2,000 lb-f (907.03 kg-f), or 2,500 lb-f (1133.794 kg-f), or 3,000 lb-f (1360.54 kg-f); and/or (iv) the coated conductor passes the horizontal burn test; and/or (v) the coated conductor is halogen-free; and the composition has one, some, or all of the following properties: (1) a tensile stress at break from 1,000 psi (6.90 MPa), or 2,000 psi (13.79 MPa), or 2,100 psi (14.48 MPa) to 2,200 psi (15.17 MPa), or 2,500 psi (17.24 MPa), or 3,000 psi (20.68 MPa), or 4,000 psi (27.58 MPa), or 5,000 psi (34.47 MPa); and/or (2) a tensile elongation at break from 100%, or 300%, or 400%, or 430% to 440%, or 450%, or 500%, or 600%, or 700%, or 800%; and/or (3) a hot creep from 0%, or 1%, or 2%, or 5%, or 10%, or 15%, or 20%, or 25%, or 30%, or 35% to 40%, or 50%, or 60%, or 70%, or 75%, or 80%, or 90%, or 100%, or 150%, or 170% at 0.2 MPa and 150° C.
[0186] In an embodiment, the coating contains, consists essentially of, or consists of a composition that contains, consists essentially of, or consists of:
[0187] (A) from 20 wt %, or 30 wt %, or 40 wt %, or 50 wt % to 55 wt %, or 60 wt %, or 65 wt %, or 70 wt %, or 75 wt %, based on the total weight of the composition, of a polymeric blend containing, consisting essentially of, or consisting of: (i) from 50 wt %, or 55 wt %, or 60 wt %, or 65 wt % to 70 wt %, or 75 wt %, or 80 wt % silane-functionalized polyolefin (e.g., a Si-g-PE); (ii) from 1 wt %, or 5 wt %, or 10 wt %, or 15 wt %, or 20 wt %, or 25 wt % to 30 wt %, or 35 wt %, or 40 wt %, or 45 wt % of a first ethylene-based polymer (e.g., an ethylene plastomer or elastomer, such as an ethylene/C.sub.4-C.sub.8 α-olefin copolymer); (iii) from 1 wt %, or 5 wt % to 10 wt %, or 15 wt %, or 20 wt %, or 25 wt %, or 30 wt %, or 35 wt %, or 40 wt %, or 45 wt % of a second ethylene-based polymer (e.g., a MAH-grafted ethylene/C.sub.4-C.sub.8 α-olefin copolymer); and (iv) from 0.1 wt %, or 0.5 wt %, or 0.8 wt % to 1.0 wt %, or 5 wt %, or 10 wt %, or 15 wt %, or 20 wt %, or 25 wt %, or 30 wt %, or 35 wt %, or 40 wt %, or 45 wt % of a third ethylene-based polymer (e.g., an LDPE), based on the total weight of the polymeric blend, wherein each of the first ethylene-based polymer, the second ethylene-based polymer, and the third ethylene-based polymer is structurally, compositionally, and/or physically distinct;
[0188] (B) from 20 wt %, or 25 wt %, or 30 wt %, or 35 wt %, or 40 wt % to 42 wt %, or 45 wt %, or 50 wt %, or 55 wt %, or 60 wt %, or 65 wt %, or 70 wt %, or 75 wt %, or 80 wt % of the halogen-free flame retardant (e.g., a metal hydroxide);
[0189] (C) from 0.10 wt %, or 0.15 wt %, or 0.20 wt % to 0.25 wt %, or 0.30 wt %, or 0.35 wt %, or 0.40 wt %, or 0.45 wt %, or 0.50 wt % HALS having a Mw greater than 5,000 Dalton (e.g., a HALS of Structure (H)); and
[0190] (D) from 0 wt %, or greater than 0 wt %, or 0.001 wt %, or 0.002 wt %, or 0.005 wt %, or 0.006 wt % to 0.007 wt %, or 0.008 wt %, or 0.009 wt %, or 0.01 wt %, or 0.1 wt %, or 0.2 wt %, or 0.3 wt %, or 0.4 wt %, or 0.5 wt %, 1.0 wt %, or 2.0 wt %, or 2.5 wt %, or 3.0 wt %, or 4.0 wt %, or 5.0 wt % to 6.0 wt %, or 7.0 wt %, or 8.0 wt %, or 9.0 wt %, or 10.0 wt %, or 15.0 wt %, or 20.0 wt % additive; and the coated conductor has one, some, or all of the following properties: (i) a wet IR from 800 Mohm/3.048 m, or 1,000 Mohm/3.048 m, or 1,500 Mohm/3.048 m to 5,000 Mohm/3.048 m, or 10,000 Mohm/3.048 m, or 15,000 Mohm/3.048 m, or 20,000 Mohm/3.048 m, or 30,000 Mohm/3.048 m, or 50,000 Mohm/3.048 m at 90° C. from 0 to 24 weeks; and/or (ii) a wet IR ratio from 0.4, or 0.5, or 0.6, or 0.7, or 0.8, or 0.9, or 1.0 to 1.1, or 1.5, or 2.0, or 3.0, or 5.0; and/or (iii) a crush resistance from 1,000 lb-f (453.51 kg-f), or 1,500 lb-f (680.27 kg-f), or 1,520 lb-f (689.34 kg-f) to 1,550 lb-f (702.95 kg-f), or 1,600 lb-f (725.62 kg-f), or 2,000 lb-f (907.03 kg-f), or 2,500 lb-f (1133.794 kg-f), or 3,000 lb-f (1360.54 kg-f); and/or (iv) the coated conductor passes the horizontal burn test; and/or (v) the coated conductor is halogen-free; and the composition has one, some, or all of the following properties: (1) a tensile stress at break from 1,000 psi (6.90 MPa), or 2,000 psi (13.79 MPa), or 2,100 psi (14.48 MPa) to 2,200 psi (15.17 MPa), or 2,500 psi (17.24 Mpa), or 3,000 psi (20.68 MPa), or 4,000 psi (27.58 MPa), or 5,000 psi (34.47 MPa); and/or (2) a tensile elongation at break from 100%, or 300%, or 400%, or 430% to 440%, or 450%, or 500%, or 600%, or 700%, or 800%; and/or (3) a hot creep from 0%, or 1%, or 2%, or 5%, or 10%, or 15%, or 20%, or 25%, or 30%, or 35% to 40%, or 50%, or 60%, or 70%, or 75%, or 80%, or 90%, or 100%, or 150%, or 170% at 0.2 MPa and 150° C.
[0191] In an embodiment, the coated conductor is selected from a fiber optic cable, a communications cable (such as a telephone cable or a local area network (LAN) cable), a power cable, wiring for consumer electronics, a powercable, a power charger wire for cell phones and/or computers, computer data cords, power cords, appliance wiring material, home interior wiring material, consumer electronic accessory cords, and any combination thereof.
[0192] In another embodiment, the present composition is melt-shaped into an article other than a coating on a conductor, e.g., an electrical connector or a component of an electrical connector.
[0193] The coated conductor may comprise two or more embodiments disclosed herein.
[0194] By way of example, and not limitation, some embodiments of the present disclosure will now be described in detail in the following Examples.
EXAMPLES
[0195] The materials used in the examples are provided in Table 1 below.
TABLE-US-00001 TABLE 1 Materials Component Specification Source XIAMETER ™ hydrolyzable silane monomer Dow OFS-6300 vinyltrimethylsilane (C.sub.5H.sub.12Si) Corning Silane (VTMS) LUPEROX ™ 101 organic peroxide; 2,5-bis(tert- Arkema butylperoxy)-2,5-dimethylhexane ENGAGE ™ 8402 ethylene/1-octene copolymer Dow (polyolefin elastomer); density = 0.902 g/cc; Melt Index = 30 g/10 min; Shore A = 88; Shore D = 34; Tm = 96° C. ENGAGE ™ 8200 ethylene/1-octene copolymer Dow (polyolefin elastomer) density = 0.870 g/cc; Melt Index = 5.0 g/10 min; Shore A = 66; Shore D = 17; Tm = 59° C. ENGAGE ™ 8450 ethylene/1-octene copolymer Dow (polyolefin elastomer) density = 0.902 g/cc; Melt Index = 3.0 g/10 min Shore A = 90; Shore D = 41; Tm = 97° C. DOW ™ linear low density polyethylene Dow LLDPE 1648 (LLDPE); density = 0.920 g/cc; Melt Index = 3.5 g/10 min; Tm = 206° C. AMPLIFY ™ MAH-grafted ethylene/butene Dow GR 208 copolymer; density = 0.902 g/cc; Melt Index = 3.3 g/10 min; Shore A = 96; Shore D = 36; Tm = 177° C. AMPLIFY ™ ethylene-ethyl acrylate (EEA) Dow EA 100 copolymer; 15 wt % ethyl acrylate; density = 0.930 g/cc; Melt Index = 1.3 g/10 min; Shore A = 87; Shore D = 37; Tm = 98.9° C. SI-LINK ™AC ethylene/silane copolymer; 1.5 wt % Dow DFDB-5451 NT vinyltrimethoxysilane; density = 0.922 g/cc; Melt Index = 1.5 g/10 min; Tm = 149-210° C. KISUMA ™ 5J magnesium hydroxide Mg(OH).sub.2; Kisuma flame retardant SAYTEX ™ 8010 decabromodiphenylethane; Albemarle brominated flame retardant Corporation ethane-1,2-bis(pentabromophenyl); Mw = 971.2 Dalton MICROFINE ™ antimony trioxide; flame Great A09 retardant synergist Lakes BRIGHTSUN ™ antimony trioxide; flame China HB500 retardant synergist Antimony ZOCO ™ 104 zinc oxide; flame retardant synergist Zochem Inc. MB50-002 50 wt % dimethylvinylsilyl terminated Dow Masterbatch polydimethylsiloxane (PDMS) Corning dispersed in LDPE LDPE Melt Index = 8.0 g/10 min; PDMS Mn = 356,700 g/mol.sup.1; PDMS Mw = 647,266 g/mol.sup.1; PDMS Mw/Mn = 1.82.sup.1 hexadecyltri- moisture scavenger; Molecular Sigma- methoxysilane Weight = 346.62 g/mol Aldrich IRGANOX ™ pentaerythritol tetrakis[3-[3,5-di-tert- BASF 1010 FF butyl-4-hydroxyphenyl]propionate sterically hindered phenol antioxidant; density = 1.116 g/cc; Tm = 117.1° C. LOWINOX ™ 1,2-bis(3,5-di-tert-butyl-4- Addivant MD24 PW hydroxyhydrocinnamoyl)hydrazine; metal deactivator and hindered phenolic antioxidant FUTURECHEM ™ Oxalyl bis(benzylidene)hydrazide FutureFuel OABH (OABH); metal deactivator; Molecular Weight = 294.31 g/mol SI-LINK ™ Silanol Condensation Catalyst Dow DFDA-5481 Masterbatch containing a blend of 1- Natural butene/ethene polymer, ethene (DFDA-5481 MB) homopolymer, a phenolic compound, dibutyltin dila urate (DBTDL), and a phenolic hydrazide compound FASCAT ™ 4202 dibutyltin dilaurate (DBTDL); PMC silanol condensation catalyst UVASORB ™ hindered amine light stabilizer 3V Sigma HA10 (CAS 136504-96-6) Mw = 11,600 Dalton; Structure (H) (depicted above) USA SABOT ™ STAB hindered amine light stabilizer; SABO UV-119 CAS 106990-43-6; Mw = 2,286 S.p.A. Dalton TINUVIN ™ 328 benzotriazole ultraviolet (UV) BASF absorber CHIMMASORB- benzophenone UV absorber BASF 81 ™ MB 54 masterbatch containing 97 wt % AMPLIFY ™ EA 100 and 3 wt % SABO ™ STAB UV-119, based on total weight of the masterbatch .sup.1Based on the average of three samples. Future Fuel = Future Fuel Chemical Company Kisuma = Kisuma Chemicals (Kyowa Chemical) Dow = The Dow Chemical Company China Antimony = China Antimony Chemicals PMC = PMC Organometallix
A. Production of Silane-Grafted Polyethylene (Si-g-PE)
[0196] A silane-grafted polyethylene is prepared by reactive extrusion through a twin-screw extruder. 1.8 wt % of vinyltrimethoxysilane (VTMS) and 900 ppm of LUPEROX™ 101 (based on the total weight of base resin (ENGAGE™ 8402)) are weighed and mixed together followed by from 10 to 15 minutes of magnetic stirring to achieve a uniform liquid mixture. The mixture is placed on a scale and connected to a liquid pump injection. Base resin ENGAGE™ 8402 is fed into the main feeder of the ZSK-30 extruder. The barrel temperature profile of the ZSK-30 extruder is set as follows: 2-3: 160° C.; 4-5: 195° C.; 6-7: 225° C.; 8-9: 225° C.; 10-11: 170° C.; with a pellet water temperature as near to 10° C. (50° F.) as possible, and a chiller water temperature as near to 4° C. (40° C.) as possible.
[0197] The amount of VTMS grafted to the polyethylene is determined by infrared spectroscopy. Spectra are measured with a Nicolet 6700 FTIR instrument. The absolute value is measured by FTIR mode without the interference from surface contamination. The ratio of the absorbances at 1192 cm-1and 2019 cm-1 (internal thicknesses) is determined. The ratio of the 1192/2019 peak heights is compared to standards with known levels of VTMS in XIAMETER™ OFS-6300 Silane. The grafted VTMS content of the silane-grafted polyethylene (Si-g-PE) is 1.7 wt %, based on the total weight of the Si-g-PE.
B. Production of Coated Conductors Using Si-g-PE
[0198] The Si-g-PE is added into a Brabender at around 140° C. and the remaining components (except the silanol condensation catalyst (SI-LINK™ DFDA-5481Natural)) are added into the bowl after the Si-g-PE is melted in amounts as specified in Table 2 below. The mixture is mixed for about 5 minutes.
[0199] The mixture is then pelletized into small pieces for wire extrusion. In the extrusion step, the silanol condensation catalyst masterbatch (SI-LINK™ DFDA-5481 Natural), is added with the pelletized mixture to extrude the composition onto 14 AWG single strand copper wire with a diameter of 0.064 inches (1.6256 mm). The composition forms a coating on the conductor. The coating is in direct contact with the conductor. The coating wall thickness is set around 30 mil (762 μm) and the extrusion temperature is from 140° C. to a head temperature of 165° C. The concentration of silanol condensation catalyst (DBTDL) in the overall composition is in the range of 0.01 wt % to 0.5 wt %.
[0200] The amount of each component present in each final composition, prior to extrusion and cure (i.e., crosslinking), is provided in Table 2 below. In other words, the wt % of each component for the individual samples is provided as the amount of each component in the formulation that is melt blended in the extruder, prior to moisture-induced crosslinking (said crosslinking occurring after extrusion).
[0201] The coated conductors are cured in a 90° C. water bath overnight (16 hours) and the cured wires are cut into segments of varying lengths for testing. The properties of the samples, including wet IR, are measured after curing (crosslinking).
[0202] The properties of each sample are provided in Table 2 below. The amounts provided in Table 2 are in weight percent, based on the total weight of the respective composition. In Table 2, “CS” refers to a comparative sample and “NM” refers to a value not measured.
[0203] As shown in Table 2, a comparative coated conductor with a coating composition containing (A) Si-g-PE, (B) a halogen-free flame retardant (KISUMA™ 5J), and (C) a HALS having a Mw less than 5,000 Dalton (SABO™ STAB UV-119) (CS 1) exhibits a wet IR of less than 800 Mohm/3.048 m at 90° C. from 6 hours to 24 weeks, and a Wet IR Ratio of less than 0.4.
[0204] CS 2 is a comparative coated conductor with a coating that lacks a HALS, and instead contains (A) Si-g-PE and (B) a halogen-free flame retardant (KISUMA™ 5J), and is not light stabilized. In other words, the coating composition of CS 2 is not protected from the effects of photo-oxidation, making the CS 2 coating unsuitable for wire and cable applications with UV exposure.
[0205] Applicant unexpectedly found that a coated conductor with a coating composition containing (A) Si-g-PE, (B) a halogen-free flame retardant (KISUMA™ 5J), and (C) a HALS having a Mw greater than 5,000 Dalton (UVASORB™ HA10) (Ex 1 and Ex 2) advantageously exhibits a wet IR of greater than 500 Mohm/3.048 m at 90° C. from 6 hours to 24 weeks, and a Wet IR Ratio greater than 0.4. In fact, Ex1advantageously exhibits a wet IR of greater than 800 Mohm/3.048 mat 90° C. from 6 hours to 24 weeks.
TABLE-US-00002 TABLE 2 Ex 1 CS 1 CS 2 Ex 2 CS 3 Si-g-PE 35.31 35.31 35.39 35.20 35.31 ENGAGE ™ 8200 12.45 12.45 12.47 12.41 12.45 ENGAGE ™ 8450 2.35 2.35 2.36 2.34 2.35 AMPLIFY ™ GR 208 3.59 3.59 3.60 3.58 3.59 KISUMA ™ 5J (Mg(OH).sub.2) 41.89 41.89 41.97 41.76 — SAYTEX ™ 8010 (brominated flame retardant) — — — — 31.42 MICROFINE ™ A09 (antimony trioxide) — — — — 10.47 UVASORB ™ HA10 (HALS, Mw = 11,600 Dalton) 0.20 — — 0.50 — SABO ™ STAB UV-119 (HALS, Mw = 2,286 Dalton) — 0.20 — — 0.20 MB50-002 Masterbatch 1.80 1.80 1.80 1.80 1.80 hexadecyltrimethoxysilane 1.47 1.47 1.47 1.47 1.47 IRGANOX ™ 1010 FF 0.31 0.31 0.31 0.31 0.31 FUTURECHEM ™ OABH 0.04 0.04 0.04 0.04 0.04 SI-LINK ™ DFDA-5481 Natural 0.59 0.59 0.59 0.59 0.59 Total wt % 100 100 100 100 100 Hot Creep (%) 38.20 37.77 NM 48.80 141.02 Tensile Stress at Break (psi) 2,119 2,163 2,064 1,302 1,168 Tensile Stress at Break (MPa) 14.61 14.91 14.23 8.98 8.05 Tensile Strain at Break (%) 433 441 510 210 357 Horizontal Burn: charred length (mm) 40 47 NM NM NM Horizontal Burn Pass or Fail Pass Pass NM NM NM Crush Resistance (lb-f) 1,529 1,505 NM NM NM Crush Resistance (kg-f) 693.42 682.54 NM NM NM Wet IR at 90° C. 6 hours 4810 3170 4120 4939 636 (Mohm/3.048 m) 1 week 4270 3520 4990 5045 2295 2 weeks 4270 438 4710 5369 2733 3 weeks 3720 3060 4310 5603 3479 4 weeks 3800 1650 3750 5810 4126 5 weeks 4280 1030 1990 3090 5770 6 weeks 4250 2970 2340 2410 6870 7 weeks 3920 750 2130 1430 8250 8 weeks 4430 755 673 2410 9130 9 weeks 4520 726 2760 1650 11100 10 weeks 4390 NM 3700 754 10400 11 weeks 4400 NM 2540 690 11800 12 weeks 4110 NM 2600 588 13100 13 weeks 4740 NM 2270 539 13400 14 weeks 5110 NM 3810 924 14100 15 weeks 4210 NM 3700 1050 14900 16 weeks 4160 NM 3980 963 14600 17 weeks 5310 NM 2250 704 15800 18 weeks 2820 NM 2340 655 16300 19 weeks NM NM 2390 679 16600 20 weeks 2270 NM 1740 924 15600 21 weeks 1560 NM 2130 1390 17600 22 weeks 1770 NM 1950 1560 17300 23 weeks 2360 NM 1770 539 17900 24 weeks 2270 NM 4120 924 17900 Average of weeks 4-6 4110 1883 2693 3770 5589 Average of weeks 7-9 4290 744 1854 1830 9493 Wet IR Ratio (Average of weeks 7-9/Average of weeks 4-6) 1.04 0.39 0.69 0.49 1.70
[0206] CS 3 is a comparative coated conductor with a coating composition containing (A) Si-g-PE, (B) a brominated flame retardant (SAYTEX™ 8010), and (C) a HALS having a Mw less than 5,000 Dalton (SABO™ STAB UV-119). CS 3 exhibits a wet IR of greater than 800 Mohm/3.048 m at 90° C. from 6 hours to 24 weeks. Thus, CS 3 demonstrates that coating compositions containing halogenated flame retardants do not exhibit the problem of low wet IR (i.e., a wet IR of less than 500 Mohm/3.048 m at 90° C. from 6 hours to 24 weeks and/or a Wet IR Ratio of less than 0.4) that exists in coating compositions that contain halogen-free flame retardants (compare CS 3 with CS 1).
[0207] UVASORB™ HA10 and SABO™ STAB UV-119 each has piperidine functional groups. However, at the same loading, UVASORB™ HA10 (Mw=11,600 Dalton) improves the wet IR performance of the sample coating composition, or retains an acceptably high wet IR (i.e., a wet IR of greater than 800 Mohm/3.048 m at 90° C. from 6 hours to 24 weeks) and a Wet IR Ratio greater than 0.4, while CHIMASORB™ 119 (Mw=2,286 Dalton) impairs the wet IR performance of the sample coating composition.
C. Production of Coated Conductors Using Ethylene/Silane Copolymer
[0208] Masterbatches are prepared by mixing all of the components of Table 3 except for the SI-LINK™ AC DFDB-5451 NT (ethylene/silane copolymer) using a BANBURY™ mixer. The mixing is done in four phases with each component hand charged to the mixer prior to the start of the first phase. Half of the polymer base resin (DOW™ LLDPE 1648) is added to the mixer first. All the inorganic fillers and additives are then charged with the remaining polymer base resin added as a top layer. The first mixing phase uses a low ram pressure setting of 103 kPa (15 psi) and is allowed to run for 30 seconds. The second mixing phase uses a high ram pressure setting of 345 kPa (50 psi) with the ram raise occurring after a mixing temperature of 112.8° C. (235° F.) is reached. The third and fourth phases both use ram pressures of 241 kPa (35 psi) and ram raises at 140.6° C. (285° F.) and 160° C. (320° F.), respectively. The mixer jacket is neither heated or cooled, but kept neutral while the mixer rotor uses cooling water to maintain a temperature of 15.6° C. (60° F.). The total mixing time is approximately 4 minutes.
[0209] The masterbatches are melt mixed at a 58.1 wt % loading with SI-LINK™ AC DFDB-5451NT (ethylene/silane copolymer) and extruded onto 14 AWG (2.08 mm.sup.2) solid copper conductors (yielding the wt % loadings of various components shown in Table 3) to make the compositions and wires of Table 3. In order to avoid premature crosslinking during extrusion, the masterbatches are dried before extrusion using a Con-Air™ desiccant dryer. The drying temperature is set to 60° C. (140° F.) and re-circulated dry air is used with a dew point setting of −40° C. (−40° F.). Drying is conducted over a 24 hours period. The dried masterbatches are weighed and sealed in foil bags prior to use in wire extrusion.
[0210] The experimental procedure used to make the wire specimens of Table 3 is as follows: Three batches of each formulation of Table 3 (5.44 kg (12 lb) each) are hand mixed and charged to the hopper feeder of the extruder. In this way, the masterbatch and the SI-LINK™ AC DFDB-5451 NT (ethylene/silane copolymer) are melt-mixed during wire extrusion to make wire constructions (14 AWG solid copper wire, 33 mil wall thickness). Each composition contains 58.1 wt % masterbatch and 41.9 wt % SI-LINK™ AC DFDB-5451 NT, based on the total weight of the composition. The wires are fabricated using a 2.5-inch Davis Standard extruder with a double-flighted Maddock™ screw and 20/40/60/20 mesh screens, at the following set temperatures (° C.) across zone 1/zone 2/zone 3/zone 4/zone 5/head/die: 129.4/135.0/143.3/148.9/151.7/165.6/165.6. The length-to-diameter (L/D) ratio of the screw is 26 (measured from the beginning of the screw flight to the screw tip) or 24 (measured from the screw location corresponding to the end of the feed casing to the screw tip). The wire construction are fabricated using screw speed of 43 rotations per minute (rpm) and line speed of 91.44 meters per minute (300 feet per minute). The wires are subsequently cured in a hot water bath set at 90° C. for at least 18 hours, to effect crosslinking of the insulation layer. After cure in the water bath, the wires are aged in an air circulating oven for 7 days at 121° C. or in a Xenon Arc™ weatherometer for 720 hours. Properties of the insulation layer or wire construction are measured after cure in the 90° C. water bath, and (in the case of tensile properties) also after aging in the 121° C. oven or the Xenon Arc™ weatherometer.
TABLE-US-00003 TABLE 3 Ex 3 Ex 4 CS 4 CS 5 SI-LINK ™ AC DFDB-5451 NT 41.9 41.9 41.9 41.9 (ethylene/silane copolymer) DOW ™ LLDPE 1648 13.78 13.78 13.78 13.78 SAYTEX ™ 8010 (brominated 21.50 21.50 21.50 21.50 flame retardant) BRIGHTSUN ™ HB500 16.54 16.54 16.54 16.54 (antimony trioxide) ZOCO ™ 104 (zinc oxide) 4.97 4.97 4.97 4.97 MB 54(97 wt % AMPLIFY ™ EA 0.23 0.23 0.23 0.23 100 and 3 wt % SABO ™ STAB UV-119).sup.1 SABO ™ STAB UV-119 — — 0.35 0.35 (HALS, Mw = 2,286 Dalton) UVASORB ™ HA10 (HALS, 0.35 0.35 — — Mw = 11,600 Dalton) TINUVIN ™ 328 (UV absorber) — 0.35 — 0.35 CHIMMASORB-81 ™ (UV absorber) 0.35 — 0.35 — IRGANOX ™ 1010 FF (antioxidant) 0.17 0.17 0.17 0.17 FASCAT ™ 4202 (silanol 0.13 0.13 0.13 0.13 condensation catalyst) LOWINOX ™ MD24 PW 0.08 0.08 0.08 0.08 (antioxidant) Total wt % 100 100 100 100 Hot Creep (%) 29 29 28 30 Hot Deformation (%) 13 12 13 14 Retained ACBD after 92 90 7 52 Glancing Impact (%) Tensile Stress at Break (psi) 2013 2280 2191 2170 Tensile Stress at Break (MPa) 13.88 15.72 15.11 14.96 Tensile Strain at Break (%) 320 310 280 304 Retained Tensile Strength after 91 92 92 93 7 days in an oven at 121° C. (%) Retained Tensile Elongation after 84 84 90 85 7 days in an oven at 121° C. (%) Retained Tensile Strength after 90 89 87 92 30 days in weatherometer Retained Tensile Elongation after 81 78 21 79 30 days in weatherometer Crush Resistance (lb-f) 1571 1757 1660 1400 Crush Resistance (kg-f) 712.47 796.83 752.83 634.92 Horizontal Burn Pass or Fail Pass Pass Pass Pass Horizontal Burn: charred length (mm) 34 46 34 41 VW-1 Pass or Fail Pass Pass Pass Pass VW-1: Maximum Burn Duration (sec) 24 28 35 28 VW-1: uncharred length (mm) 154 173 141 178 .sup.1based on the total weight of the MB 54 masterbatch
[0211] A comparative coated conductor with a coating composition containing (A) ethylene/silane copolymer (SI-LINK™ AC DFDB-5451 NT), (B) a halogenated flame retardant (SAYTEX™ 8010), and (C) a HALS having a Mw less than 5,000 Dalton (SABO™ STAB UV-119) (CS 4 and CS 5) exhibits (i) a retained ACBD after glancing impact of less than 75%, (ii) a retained tensile strength after 7 days in an oven at 121° C. of less than 94%, (iii) a retained tensile elongation after 7 days in an oven at 121° C. of less than 87%, (iv) a retained tensile strength after 30 days in a weatherometer of less than 95%, and (v) a retained tensile elongation after 30 days in a weatherometer of less than 81%.
[0212] Applicant unexpectedly found that a coated conductor with a coating composition containing (A) ethylene/silane copolymer (SI-LINK™ AC DFDB-5451 NT), (B) a halogenated flame retardant (SAYTEX™ 8010), and (C) a HALS having a Mw greater than 5,000 Dalton (UVASORB™ HA10) (Ex 3 and Ex 4) advantageously exhibits (i) a retained ACBD after glancing impact greater than 75%, (ii) a retained tensile strength after 7 days in an oven at 121° C. greater than 94%, (iii) a retained tensile elongation after 7 days in an oven at 121° C. greater than 87%, (iv) a retained tensile strength after 30 days in a weatherometer greater than 95%, and (v) a retained tensile elongation after 30 days in a weatherometer greater than 81%.
[0213] It is specifically intended that the present disclosure not be limited to the embodiments and illustrations contained herein, but include modified forms of those embodiments including portions of the embodiments and combinations of elements of different embodiments as come within the scope of the following claims.