Azadeh
Soroudi
a,
Yingwei
Ouyang
a,
Fritjof
Nilsson
bc,
Ida
Östergren
a,
Xiangdong
Xu
d,
Zerui
Li
a,
Amir Masoud
Pourrahimi
a,
Mikael
Hedenqvist
b,
Thomas
Gkourmpis
e,
Per-Ola
Hagstrand
e and
Christian
Müller
*a
aDepartment of Chemistry and Chemical Engineering, Chalmers University of Technology, 41296 Göteborg, Sweden
bDepartment of Fibre and Polymer Technology, School of Engineering Sciences in Chemistry, Biotechnology and Health, KTH Royal Institute of Technology, 10044 Stockholm, Sweden
cFSCN research centre, Mid Sweden University, 85170 Sundsvall, Sweden
dDepartment of Electrical Engineering, Chalmers University of Technology, 41296 Göteborg, Sweden
eInnovation & Technology, Borealis AB, 44486 Stenungsund, Sweden. E-mail: christian.muller@chalmers.se
First published on 20th May 2022
Octyl-silane-coated Al2O3 nanoparticles are found to be a promising conductivity-reducing additive for thermoplastic ternary blends comprising low-density polyethylene (LDPE), isotactic polypropylene and a styrenic copolymer. The ternary blend nanocomposites were prepared by compounding the blend components together with an LDPE-based masterbatch that contained the nanoparticles. The nanoparticles did not affect the superior stiffness of the ternary blends, compared to neat LDPE, between the melting temperatures of the two polyolefins. As a result, ternary blend nanocomposites comprising 38 wt% polypropylene displayed a storage modulus of more than 10 MPa up to at least 150 °C, independent of the chosen processing conditions. Moreover, the ternary blend nanocomposites featured a low direct-current electrical conductivity of about 3 × 10−15 S m−1 at 70 °C and an electric field of 30 kV mm−1, which could only be achieved through the presence of both polypropylene and Al2O3 nanoparticles. This synergistic conductivity-reducing effect may facilitate the design of more resistive thermoplastic insulation materials for high-voltage direct current (HVDC) power cables.
Significant academic research efforts are currently dedicated to the development of materials concepts that permit to reduce the direct-current (DC) electrical conductivity σDC of insulation materials at high electric fields. A reduction in σDC may allow the design of HVDC cables that can operate at a higher transmission voltage and hence incur lower losses. LDPE and XLPE feature values of σDC ≥ 10−14 S m−1 at 30 kV mm−1 and 70 °C,10 which are common design parameters for the highest electric field stress and operating temperature that the insulation layer of an HVDC cable may experience.8 Conductivity-reducing additives such as metal oxide nanoparticles,11 organic semiconductors including fullerenes12 and conjugated polymers,13 aromatic voltage stabilizers,14–16 as well as high-density polyethylene (HDPE)10 can be added to the polyethylene-based insulation material to achieve a further reduction in σDC. Moreover, the combination of different additives such as Al2O3 nanoparticles and HDPE can give rise to a synergistic conductivity-reducing effect.17
PP grades developed for capacitor type applications display excellent electrical properties18 and an electrical conductivity as low as σDC ≈ 10−15 S m−1 at 30 kV mm−1 and 70 °C has been reported for isotactic PP.3 A number of studies have recently investigated nanocomposites of polyolefin-based insulation materials and metal oxide nanoparticles composed of MgO,19–21 ZnO,21–23 TiO2,21,24 SiO225,26 or Al2O3.21,27,28 The strongest conductivity-reducing effect is typically observed if the metal oxide nanoparticles are surface-modified with, e.g., silane coupling agents terminated with an alkyl chain.19,29
We have recently explored blends of PP and LDPE to which we added a linear triblock copolymer, polystyrene-b-(ethylene-co-butylene)-b-polystyrene (SEBS),3 which modifies the interface between domains of the two immiscible polyolefins. Ternary blends with a sufficiently high content of both PP and SEBS displayed a high storage modulus of more than 10 MPa at temperatures up to TPPm, which may allow the design of insulation materials with higher operating temperatures. Moreover, the addition of PP to LDPE considerably reduced the electrical conductivity.30
Here, we show that the addition of Al2O3 nanoparticles surface-modified with n-octyltriethoxysilane allows to further reduce the electrical conductivity of SEBS:
PP
:
LDPE ternary blends without affecting the high-temperature dimensional stability. Al2O3 nanoparticles are a commonly used additive for plastics because they are fairly inert, odourless, inexpensive and white. Furthermore, they can be surface-functionalized for good dispersion in molten LDPE and for improving its insulating properties.17,31 The presence of both Al2O3 nanoparticles and PP has a synergistic conductivity-reducing effect, reaching an electrical conductivity close to neat PP, which may aid the design of highly insulating materials.
LDPE (wt%) | PP (wt%) | SEBS (wt%) | Al2O3 (wt%) | E′ at 150 °C (MPa) | σ DC at 70 °C (10−15 S m−1) | |
---|---|---|---|---|---|---|
a Single measurement, a relative error of Δx = 10% is assumed. b Mean of two measurements of two separately compounded samples, error calculated according to Δx = (xmax − xmin)/2. c Data from ref. 30. | ||||||
LDPE | 100 | — | — | — | n.a. | 43.0 ± 4.3a |
LDPE![]() ![]() |
98.7 | — | — | 1.3 | n.a. | 9.6 ± 1.5b |
PP | — | 100 | — | — | 220 | 1.4 ± 0.1c |
SEBS | — | — | 100 | — | 2 | 10.1 ± 1.0a |
SEBS![]() ![]() ![]() ![]() |
42 | 38 | 20 | — | 15 | 4.3 ± 0.4a |
SEBS![]() ![]() ![]() ![]() ![]() ![]() |
40.7 | 38 | 20 | 1.3 | 19 | 2.6 ± 0.4b |
Scanning electron microscopy (SEM) on cryofractured, etched and sputtered surfaces was carried out to examine the microstructure of the nanocomposites. SEM images of a 98.7:
1.3 LDPE
:
Al2O3 nanocomposite feature distinct Al2O3 nanoparticles embedded in the LDPE matrix (Fig. 2a; SEM images of the same LDPE grade can be found in ref. 10). The 20
:
38
:
42 SEBS
:
PP
:
LDPE ternary blend displayed a heterogeneous microstructure (Fig. 2b). The etching process that was employed predominately removes amorphous material, resulting in voids where the SEBS copolymer used to reside. Hence, we assign the regions that contain voids to SEBS, intermixed with PP, which are interspersed with domains of LDPE (Fig. 2b). The regions composed of PP and SEBS (voids in the SEM image shown in Fig. 2b) appear continuous, which is consistent with a previous study.30 SEM images of the 20
:
38
:
40.7
:
1.3 SEBS
:
PP
:
LDPE
:
Al2O3 ternary blend nanocomposite feature a comparable microstructure with continuous PP
:
SEBS domains interspersed with LDPE domains (Fig. 2c). The Al2O3 nanoparticles were added via an LDPE
:
Al2O3 masterbatch and hence can be expected to predominately reside within LDPE domains, as confirmed by SEM images of the ternary blend nanocomposite (Fig. 2c). We also investigated LDPE-rich ternary blend nanocomposites with a formulation of 5
:
24
:
68.9
:
2.1 SEBS
:
PP
:
LDPE
:
Al2O3, which featured a microstructure composed of SEBS:PP droplets in a continuous LDPE matrix (Fig. S1†). Again, the Al2O3 nanoparticles were located within LDPE.
Differential scanning calorimetry (DSC) was carried out to explore whether some of the Al2O3 nanoparticles have entered PP domains during compounding. A comparison of DSC cooling thermograms of the 20:
38
:
42 SEBS
:
PP
:
LDPE ternary blend and 20
:
38
:
40.7
:
1.3 SEBS
:
PP
:
LDPE:Al2O3 ternary blend nanocomposite indicate that the peak crystallization temperature of PP shifts from T0c ≈ 112 °C to Tnucc ≈ 115 °C, which we ascribe to the presence of Al2O3 nanoparticles that nucleate PP (Fig. 3a and Table S2†). Since the two materials feature a similar microstructure, we propose that some of the nanoparticles have entered PP domains (or reside at the PP domain interface) and act as a nucleating agent (note that TPEc also increased from 96 °C to 98 °C, which would again be consistent with a nucleation type effect). To investigate the ability of Al2O3 to nucleate PP in more detail we calculated the nucleating efficiency of Al2O3 with respect to optimally self-seeded material according to ηnuc = (Tnucc − T0c)/(Tmaxc − T0c) where Tnucc, T0c and Tmaxc are the peak crystallization temperatures of nucleated material, non-nucleated material and optimally nucleated material, respectively.33Tmaxc can be obtained through self-seeding where the material is only allowed to melt in part, which yields Tmaxc ≈ 141 °C for PP in case of the 20
:
38
:
42 SEBS
:
PP
:
LDPE ternary blend (Fig. S2†). Hence, we obtain ηnuc ≈ 10% for PP, which is low compared to nucleating agents such as dimethyldibenzylidene sorbitol (DMDBS).34
![]() | ||
Fig. 3 (a) DSC cooling thermograms and (b) WAXS diffractograms of LDPE (grey), PP (brown), 20![]() ![]() ![]() ![]() ![]() ![]() ![]() ![]() ![]() ![]() ![]() ![]() ![]() ![]() ![]() ![]() ![]() ![]() ![]() ![]() |
The crystallinity of PP and PE was not overly affected by the Al2O3 nanoparticles (Table S2†), in agreement with previous reports.17,27 Wide angle X-ray scattering (WAXS) diffractograms of the ternary blend and ternary blend nanocomposite (Fig. 3b) indicate that in case of the ternary blend, only PP α-polymorph crystallites are present. Instead, the presence of Al2O3 nanoparticles promotes the formation of a fraction of β-polymorph crystallites as evidenced by the emergence of a clear peak at q = 1.16 Å−1, which is consistent with a nucleation type effect.35
In a further set of experiments, we used dynamic mechanical analysis (DMA) to record the storage modulus E′ of the investigated materials as a function of temperature (Fig. 4). The DMA thermograms of neat LDPE and the 98.7:
1.3 LDPE
:
Al2O3 nanocomposite show comparable behavior and a strong reduction in modulus above TLDPEm ≈ 110 °C. Likewise, the DMA thermograms recorded for the 20
:
38
:
42 SEBS
:
PP
:
LDPE ternary blend and the corresponding nanocomposite follow a similar trend (Fig. 4), which is consistent with the comparable microstructure inferred from SEM (see Fig. 2) and similar crystallinity (Table S2†). Gratifyingly, both materials feature a relatively high modulus in the temperature range TLDPEm < T < TPPm, with a value of E′ = 15 MPa at 150 °C above which PP starts to melt (Table 1). In this temperature range the storage modulus of the ternary blend is about two orders of magnitude higher than the rubber plateau value of XLPE, which is today widely used as an HVDC insulation material. Furthermore, we observed a comparable thermomechanical behaviour independent of the cooling rate used for sample preparation, ranging from −1 to −20 °C min−1 (Fig. S3†), which indicates that the here investigated formulations are not sensitive to slight changes in processing conditions.
We went on to investigate the impact of the octyl-silane-coated Al2O3 nanoparticles on the electrical conductivity (Fig. 5). For neat LDPE we measure a value of σDC ≈ 43 × 10−15 S m−1 at 70 °C and 30 kV mm−1 (Table 1), which is in agreement with previous studies where we have investigated the same LDPE grade.3,32 The presence of 1.3 wt% Al2O3 nanoparticles reduced the electrical conductivity to 9.6 × 10−15 S m−1, which confirms that the here employed nanoparticles have a clear conductivity-reducing effect. The mechanism behind the reduced DC conductivity displayed by nanocomposites is not yet fully established. However, several hypotheses have been proposed. Dispersed nanoparticles in an LDPE matrix can absorb polar molecules or ions, which act as charge carriers,36,37 they can introduce deep trapping sites for electrons or holes located in the vicinity of the nanoparticle surface38–42 and they can lead to recombination of charge carriers.43
The 20:
38
:
42 SEBS
:
PP
:
LDPE ternary blend displayed a conductivity of σDC ≈ 4.3 × 10−15 S m−1 at 70 °C and 30 kV mm−1, which is 10-times lower than the value measured for neat LDPE (Table 1). We ascribe the strong reduction in σDC to the presence of PP, which thanks to its high degree of cleanliness has a conductivity of only σDC ≈ 1.4 × 10−15 S m−1. The addition of 1.3 wt% Al2O3 nanoparticles results in a further reduction in σDC to 2.6 × 10−15 S m−1 at 70 °C and 30 kV mm−1, measured for the 20
:
38
:
40.7
:
1.3 SEBS
:
PP
:
LDPE
:
Al2O3 ternary blend nanocomposite. A similar trend is also observed at 50 °C, i.e. the addition of Al2O3 nanoparticles to the ternary blend results in a material that has a lower σDC than the ternary blend without Al2O3 (Fig. S4†). SEM images indicate that the SEBS
:
PP regions are continuous (see Fig. 2), and therefore it can be anticipated that charge conduction involves SEBS:PP regions. Al2O3 nanoparticles are present in LDPE domains (see Fig. 2c) as well as in PP domains, inferred from the nucleating effect observed with DSC (see Fig. 3). We argue that Al2O3 nanoparticles function as a conductivity-reducing additive also in case of the ternary blend nanocomposite.
In a last set of experiments, we measured σDC of a ternary blend with a composition of 5:
24
:
71 SEBS
:
PP
:
LDPE, which features isolated SEBS:PP regions embedded in a continuous LDPE matrix (see Fig. S1†), as well as a corresponding binary blend with a composition of 25
:
75 PP
:
LDPE. For this LDPE-rich ternary blend we recorded a value of σDC ≈ 11.6 × 10−15 S m−1, which was reduced to 2.9 × 10−15 S m−1 in the case of the corresponding ternary blend nanocomposite containing 2.1 wt% of Al2O3 nanoparticles (Fig. S5 and Table S1†), again prepared by compounding the LDPE:Al2O3 masterbatch with SEBS and PP (see Fig. 1). We argue that also for the more LDPE-rich ternary blend nanocomposite, the Al2O3 nanoparticles function as a conductivity-reducing additive, resulting in a 4-fold reduction in σDC.
A comparison of the DC electrical conductivity measured for materials with different LDPE contents reveals that in case of formulations that do not contain any nanoparticles there is a gradual reduction in σDC with increasing amount of the foreign phase (PP or SEBS:
PP) with the lowest value obtained for neat PP (Fig. 6). In contrast, the materials that contain Al2O3 nanoparticles display a much lower σDC of about 3 × 10−15 S m−1, largely independent of the LDPE content. In case of LDPE-rich nanocomposite formulations, the reduction in σDC is more pronounced compared to corresponding formulations with a similar LDPE content but no Al2O3 nanoparticles. Evidently, the use of Al2O3 nanoparticles as a conductivity-reducing additive is a viable strategy for the design of highly resistive insulation materials, in particular in case of formulations that contain a large amount of LDPE.
Footnote |
† Electronic supplementary information (ESI) available. See DOI: https://doi.org/10.1039/d1nr08255h |
This journal is © The Royal Society of Chemistry 2022 |