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CA-3044466-C - MULTIPHASE CONDUCTIVE POLYMER COMPOSITE COMPOSITIONS

CA3044466CCA 3044466 CCA3044466 CCA 3044466CCA-3044466-C

Abstract

A composition comprises a ternary-phase polymer composite including components (A) ethylene/unsaturated ester copolymers having γρ of from < 5 to >1 mN/m; at least two additional polymers selected from the group consisting of: (B) non-polar polymers having γρ of from > 0 to < 1 mN/m selected from the group consisting of polyethylene homopolymers, silane- functionalized polyethylene homopolymers, ethylene/alpha-olefin copolymers, and silane- functionalized ethylene/alpha-olefin copolymers, (C) ethylene/unsaturated ester copolymers having a γΡ of > 5 mN/m, and (D) EPDM copolymers; and conductive filler dispersed in only one of (A) and the at least two additional polymers, wherein (i) one of the at least two additional polymers is selected from (B) and the other is selected from (C) or (D), or (ii) one of the at least two additional polymers is selected from (C) and the other is selected from (B) or (D).

Inventors

  • PAUL BRIGANDI
  • Jeffrey M. Cogen
  • John Reffner

Assignees

  • UNION CARBIDE CHEMICALS & PLASTICS TECHNOLOGY LLC
  • ROHM AND HAAS COMPANY

Dates

Publication Date
20260505
Application Date
20171113
Priority Date
20161123

Claims (10)

  1. CLAIMS: A composition comprising: a ternary-phase polymer composite comprising components: (A) at least one copolymer of ethylene with an unsaturated ester having a polar component of the surface tension ( -/) of from less than or equal to 5 milliNewtons per meter (mN/m) to greater than or equal to I mN/m; at least two additional polymers selected from the group consisting of: (B) at least one non-polar polymer having a polar component of the surface tension (y) of from greater than or equal to 0 mN/m to less than I mN/m and selected from the group consisting of polyethylene homopolymers, silanefunctionalized polyethylene homopolymers, ethylene/alpha-olefin copolymers, and silane-functionalized ethylene/alpha-olefin copolymers; (C) at least one copolymer of ethylene with an unsaturated ester having a polar component of the surface tension (l) of greater than 5 mN/m; and (D) at least one ethylene propylene diene monomer copolymer; and a conductive filler dispersed in only Component (A), wherein (i) a first of the at least two additional polymers is selected from (B) and a second of the at least two additional polymers is selected from (C) or (D), or (ii) the first of the at least two additional polymers is selected from (C) and the second of the at least two additional polymers is 20 selected from (B) or (D).
  2. 2. The composition of claim 1, wherein Component (A) is selected from the group consisting of ethylene-ethyl acrylate, ethylene-methyl acrylate, ethylene-butyl acrylate and combinations thereof.
  3. 3. The composition of any one of claims 1 and 2, wherein the conductive filler is selected 25 from the group consisting of carbon black, carbon nanotubes, graphite, graphene and combinations thereof.
  4. 4. The composition of any one of claims I to 3, wherein the ternary-phase polymer composite compnses a) Components (A), (B) and (C); or 30 b) Components (A), (C) and (D); or c) Components (A), (B) and (D). Date Re9ue/Date Received 2024-03-27 23 85332719
  5. 5. The composition of any one of claims 1 to 4, wherein Component (B) is present and is selected from the group consisting of a polyethylene homopolymer and a silane-functionalized polyethylene homopolymer.
  6. 6. The composition of any one of claims 1 to 5, wherein Component (A) is present in an 5 amount of from greater than 0 vol% to less than or equal to 40 vol%, based on the total volume of the composite and a) Component B is present in an amount of from greater than 0 vol% to less than or equal to 50 vol%, based on the total volume of the composite, or b) Component C is present in an amount of from greater than 0 vol% to less than or equal 10 to 50 vol%, based on the total volume of the composite, or c) Component D is present in an amount of from greater than 0 vol% to less than or equal to 50 vol%, based on the total volume of the composite.
  7. 7. The composition ofany one of claims 1 to 6, wherein the ternary-phase polymer composite compnses 15 a) Components (A), (B) and (C), wherein Component (A) is selected from the group consisting of ethylene-ethyl acrylate, ethylene-methyl acrylate, ethylene-butyl acrylate and combinations thereof, and wherein Component (B) is selected from the group consisting of a polyethylene homopolymer and silane-functionalized polyethylene homopolymer, and wherein Component (C) is an ethylene-vinyl acetate having a polar component of the surface tension (r) 20 of greater than 5 mN/m; or b) Components (A), (C) and (D), wherein Component (A) is selected from the group consisting of ethylene-ethyl acrylate, ethylene-methyl acrylate, ethylene-butyl acrylate and combinations thereof, and wherein Component (D) is an EPDM terpolymer; or c) Components (A), (B) and (D), wherein Component (A) is selected from the group 25 consisting of ethylene-ethyl acrylate, ethylene-methyl acrylate, ethylene-butyl acrylate and combinations thereof, and wherein Component (B) is selected from the group consisting of a polyethylene homopolymer and silane- functionalized polyethylene homopolymer, and wherein Component (D) is an EPDM terpolymer.
  8. 8. A cable comprising an semiconducting layer comprising the composition as defined in any 30 one of claims 1 to 7.
  9. 9. A cable comprising: a conductor; Date Re9ue/Date Received 2024-03-27 24 85332719 an inner semiconducting layer covering at least a portion of the conductor; an insulation layer covering at least a portion of the inner semiconducting layer; and an outer semiconducting layer covering at least a portion of the insulation layer; wherein at least one of the inner and outer semiconducting layer comprises a ternary-phase 5 polymer composite comprising components (A) at least one copolymer of ethylene with an unsaturated ester having a polar component of the surface tension ( -/) of from less than or equal to 5 milliNewtons per meter (mN/m) to greater than or equal to 1 mN/m; at least two additional polymers selected from the group consisting of: (B) at least one non-polar polymer having a polar component of the surface tension (-/) of from greater than or equal to 0 mN/m to less than 1 mN/m and selected from the group consisting of polyethylene homopolymers, silanefunctionalized polyethylene homopolymers, ethylene/alpha-olefin copolymers, and silane- functionalized ethylene/alpha-olefin copolymers; (C) at least one copolymer of ethylene with an unsaturated ester having a polar component of the surface tension(-/) of greater than 5 mN/m; and (D) at least one ethylene propylene diene monomer copolymer; and a conductive filler dispersed in only Component (A), wherein (i) a first of the at least two additional polymers is selected from (B) and a 20 second of the at least two additional polymers is selected from (C) or (D), or (ii) the first of the at least two additional polymers is selected from (C) and the second of the at least two additional polymers is selected from (B) or (D).
  10. 10. A method of conducting electricity, the method comprising applying voltage across the cable as defined in any one of claims 8 and 9. Date Re9ue/Date Received 2024-03-27

Description

MULTIPHASE CONDUCTIVE POLYMER COMPOSITE COMPOSITIONS BACKGROUND Generally, single polymer systems require a substantial concentration of conductive filler to achieve significant electrical conductivity, e.g., on the order of 10·9 to 10·3 Siem. 5 Such substantial concentrations of conductive filler increase the melt viscosity of the material while also decreasing the mechanical properties of the material. One approach to increase composite conductivity at reduced filler concentrations, and thereby minimize detrimental impact on mechanical and rheological properties, is to use multiphase polymer blends that can reduce the percolation threshold. For the case of a two-component polymer blend, 10 several studies found the percolation threshold can be reduced using two phase polymer blends where the conductive filler was incorporated into immiscible polymer blends and is governed by the percolation of the conductive filler-rich phase and the continuity of this phase in the polymer blend. The use of ternary polymer blends, i.e., three-component polymer blends, in 15 combination with conductive filler, e.g., carbon black, has also been shown to reduce the percolation threshold and achieve conductivity in a few different polymer systems. Such ternary polymer blends, however, still show significant brittleness. Depending on the use, the brittleness may be improved at the cost of an increased percolation threshold. A polymer composite composition using crosslinkable polymers and showing 20 improved, i.e., lower, percolation threshold and improved, i.e., lower, brittleness is needed. Further, such a composite composition showing improved, i.e., lower, melting point and glass transition temperature, as well as improved, i.e., increased, flexibility, is needed, particularly for cable applications. SUMMARY OF THE INVENTION 25 The disclosure provides a composition comprising: a ternary-phase polymer composite comprising components: (A) at least one copolymer of ethylene with an unsaturated ester having a polar component of the surface tension (l) of from less than or equal to 5 milliNewtons per meter (mN/m) to greater than or equal to 1 mN/m; at least two additional polymers selected from the group consisting of: 1 WO 2018/097982 PCT/0S2017/061241 (B) at least one non-polar polymer having a polar component of the surface tension Cl) of from greater than or equal to 0 mN/m to less than 1 mN/m and selected from the group consisting of polyethylene homopolymers, silane-functionalized polyethylene homopolymers, ethylene/alpha-olefin copolymers, and silane-functionalized ethylene/alpha-olefin copolymers; (C) at least one copolymer of ethylene with an unsaturated ester having a polar component of the surface tension (yP) of greater than 5 mN/m; and (D) at least one ethylene propylene diene monomer copolymer; and a conductive filler dispersed in only one of Component (A) and the at least two additional polymers, wherein (i) a first of the at least two additional polymers is selected from (B) and a second of the at least two additional polymers is selected from (C) or (D), or (ii) the first of the at least two additional polymers is selected from (C) and the second of the at least two additional polymers is selected from (B) or (D). In another embodiment, the disclosure provides a cable comprising a conductor, an inner semiconducting layer covering at least a portin of the conductor; an insulation layer covering at least a portion of the inner semiconducting layer; and an outer semiconducting layer covering t least a portion of the insulation layer, wherein at least one of the inner and 20 outer semiconducting layers comprises a ternary-phase polymer composite comprising components (A) at least one copolymer of ethylene with an unsaturated ester having a polar component of the surface tension (yP) of from less than or equal to 5 milliNewtons per meter (mN/m) to greater than or equal to 1 mN/m; at least two additional polymers selected from the group consisting of: (B) at least one non-polar polymer having a polar component of the surface tension (y) of from greater than or equal to 0 mN/m to less than 1 mN/m and selected from the group consisting of polyethylene homopolymers, silane-functionalized polyethylene homopolymers, ethylene/alpha-olefin copolymers, and silane-functionalized ethylene/alpha-olefin copolymers; 2 WO 2018/097982 PCT/0S2017/061241 (C) at least one copolymer of ethylene with an unsaturated ester having a polar component of the surface tension (l) of greater than 5 mN/m; and (D) at least one ethylene propylene diene monomer copolymer; and a conductive filler dispersed in only one of Component (A) and the at least two additional polymers, wherein (i) a first of the at least two additional polymers is selected from (B) and a second of the at least two additional polymers is selected from (C) or (D), or (ii) the first of the at least two additional polymers is selected from (C) and the second of the at least two add