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HAREDY

HAlloysite nanotubes as flame REtardant carrier in pe/eva blends for innovative formulations for wire and cable inDustrY
Funder: French National Research Agency (ANR)Project code: ANR-18-CE06-0020
Funder Contribution: 461,539 EUR
Description

To maintain its competitiveness, cable and wire industries have to continuously improve their products regarding mechanical, fire, electrical and aging properties while meeting sustainable and environmental requirements requested by the European Union. Moreover, the full implementation of the Construction Product Regulation (CPR) requires the cable companies to use new national safety levels called Euroclasses. This major change brings a unique opportunity to increase the safety level of cables in building, especially in Europe for a market size representing 1 billion €. The current materials used as sheaths for cables are based on polymer blends either with high contents of metal hydrates (>60wt%) or with intumescent systems based on ammonium polyphosphate (APP). The former dramatically decreases the mechanical performances of the wires whereas the latter is very instable toward water. In HAREDY project it is proposed to develop a controlled release flame retardant system based on linear low density polyethylene/ethylene-vinyl acetate copolymer (LLDPE/EVA) blends dedicated to the cable industry. This innovative system is based on both the encapsulation of flame retardant (FR) molecules into halloysite nanotubes (HNT) and on the control of final morphology of the LLDPE/EVA/HNT system regarding fire performances. Through this method it is possible to decrease the aging of the cable and decrease the amount of mineral filler, leading to an improvement of the mechanical properties of the cable. We propose to take benefit from the versatile character of HNT that is an inexpensive, non-toxic and naturally available resource to improve the final performances of the cables. Indeed, FR molecules (such as phosphorus molecules, triazines, pentaerythritol) will be encapsulated into the lumen to improve the HNT fireproofing propensity and to delay the aging toward water. In parallel, inner alumina and outer silica surfaces will be functionalized to control the charring process at the nanoscale and to improve the dispersion of the nanotubes in the blend, respectively. The chemical modification of HNT surfaces will also be targeted to selectively disperse the HNTs either in the EVA phase or in the LLDPE matrix or at the interface between PE and EVA to improve fire performances. LLDPE/EVA/HNT materials will be processed by twin screw extrusion and co-kneader. Processing parameters will be optimized to achieve the targeted selective dispersions. Dedicated characterization based on mechanical, aging and fire properties will be performed so as to identify the relevant treatment routes and proper localization of modified HNT, to select the most promising blend system. The selected materials will then be used to produce cables at an industrial scale. Electrical, fire and aging properties of the insulation material on one side and the definition of the design, the prototyping and the flame and fire performances of the related wire and cables systems according to the standards requested by the electric industry on the other side will be carried out. The consortium is based on three partners: two complementary academic partners (ARMINES/C2MA and UMR5223/IMP) and one industrial company that designs and supplies cables (NEXANS). ARMINES/C2MA is an expert in fireproofing polymer materials and chemical modification of mineral fillers, while UMR5223/IMP is internationally recognized for its expertise in macromolecular engineering, organic-inorganic hybrid materials, rheology and reactive processing of thermoplastic polymers. Additionally, NEXANS is a top-ranking globally cable and wire industry that improve its competitiveness thanks to the development of new products in its R&D center in Lyon. The recruitment of one Ph.D student (36 months in UMR5223/IMP) and one post-doc research assistant (18 months in ARMINES/C2MA) is planned for the 42 months project duration. A budget line of 461,5k€ is targeted.

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