What is XLPE Material Used in Cable Manufacturing?

What is XLPE material used in cable manufacturing?
Saw automation & electrical parts
What is XLPE material? Our topic today, as XLPE is a commonly used material in cable manufacturing due to its excellent chemical and thermal properties compared to other materials. In our article today, we will learn about this material, its key features, and the future developments of cables made from it.

What is XLPE material used in cable manufacturing?
What is XLPE material? It stands for Cross-Linked Polyethylene Cable, which is a type of modified plastic through molecular cross-linking, giving it many distinctive properties with high resistance to pressure and corrosion, and thermal properties that provide it with an excellent ability to insulate cables safely and with high quality.

The main characteristics of XLPE material are as follows:

• Ability to withstand temperatures of 90°C, and can reach up to 250°C in emergency situations.

• High insulation strength, making it an ideal choice for insulating electrical cables.

• Low insulation loss property, which helps reduce electrical energy loss.

• High flexibility, which aids in easy installation due to its resistance to cutting and bending.

• Good resistance to moisture, ensuring a better lifespan in humid environments.

• Good resistance to chemicals and solvents, reducing the risk of chemical corrosion.

Advantages of XLPE material
In our discussion today about what XLPE material is, and having learned about its key chemical and physical properties, we will now explore its advantages. XLPE material has many features that make it the most suitable choice in cable manufacturing, including:

• Good resistance to moisture, making it a suitable choice in humid environments.

• Also possessing good resistance to heat and humidity, making it most suitable for solar panels.

• Resistance to salinity and excess water pressure, making it a suitable choice in marine environments.

• Long lifespan and generally does not require frequent maintenance, which reduces financial costs for repeated maintenance and the need for replacement at close intervals.

Uses of XLPE in cable manufacturing
What is XLPE material? And what are its main uses in cable manufacturing? As we explained above, it is a material with distinctive chemical and physical properties that give it multiple advantages beneficial in manufacturing, and among its uses in cable manufacturing are:

Electrical cables

XLPE is used as an insulating material in high, medium, and low voltage electrical cables due to its excellent properties in transmitting electricity safely, with high quality, and reducing increased energy loss.

High voltage cables

XLPE is relied upon as an insulating material in high voltage electrical systems, which may exceed 66 kilovolts, due to its high thermal properties that give it good capabilities in withstanding high temperatures and high electrical voltage.

Communication cables

XLPE is used in the manufacture of communication cables and fiber optics because it is capable of providing the necessary protection for cables from external influences, environmental factors, and electromagnetic interference.

Architecture

XLPE cables are used in electrical equipment such as air conditioners and elevators, and are also relied upon in advanced systems within smart buildings.

Heavy industries

XLPE is relied upon in heavy industries, most notably the automotive industry, where it is used in cables inside the car due to its excellent capabilities in resisting high temperatures, oils, and solvents.

Marine

As we explained during our discussion about what XLPE material is and its advantages, we clarified that one of its main features is the ability to resist water and moisture; therefore, it is relied upon in the manufacture of marine cables due to its ability to adapt to marine and humid environments.

Underground power transmission projects

XLPE cables are considered the best in these projects because they are characterized by high resistance to moisture, corrosion, and pressure, as we explained above when discussing what XLPE material is and its advantages; making it the most effective in these projects.

What is the difference between XLPE cable and PVC cable?
After learning about what XLPE material is, we will learn about the difference between XLPE cable and PVC cable, as they are among the most famous types of cables available in the markets. There are several differences between them, which are as follows:

• Maximum conductor operating temperature: For XLPE 90°C, while for PVC 70°C.

• Maximum temperature: Reaches 250°C in XLPE cable, while it reaches 160°C in PVC cable.

• Water resistance: XLPE cables have better water resistance compared to PVC cables.

• Environmental preservation: We can say that XLPE cables are environmentally friendly because they do not produce toxic materials that harm the environment.

• Lifespan: Cables insulated with XLPE have a longer lifespan than PVC cables.

• Financial cost: Due to the multiple advantages of XLPE cables, they are higher priced compared to PVC cables.

Thus, we can say that cables insulated with XLPE material are the best in terms of performance, environmental protection, and lifespan, although they are the most expensive; making them a suitable option for those looking for better performance, with a long lifespan, and reducing toxic materials that may harm the surrounding environment.

Future developments of XLPE material in cable manufacturing
In conclusion of our discussion today about what XLPE material is, we will highlight the future developments of XLPE material in cable manufacturing. Modern electrical power systems are witnessing many developments, which require some changes to XLPE material to keep pace with these developments and adapt to them more effectively.

Among the efforts to develop XLPE material is working on developing it effectively for use in the manufacture of ultra-high voltage cables, which may reach 800 kilovolts, which enhances the transmission of electrical energy over greater distances in effective ways. Currently, it is relied upon in high voltage cables, which range from approximately 66 to 600 kilovolts.

Moreover, there are some efforts being made to develop XLPE material and give it higher thermal properties than it is now, in order to reduce the possibility of risks resulting from high temperatures. Therefore, it may be supplemented with secondary materials with high thermal resistance, including, for example: graphene and metal oxides.

Work is also being done to develop XLPE material in order to achieve better efficiency in resisting environmental factors and harsh weather conditions, such as: high or low temperatures, ultraviolet rays, acid rain; therefore, it is being supplemented with materials more resistant to these factors in order to achieve better operational efficiency in various environmental conditions.

In the context of working to protect the environment, some seek to recycle XLPE material used in cable manufacturing, but there are some obstacles to achieving this, represented in its inability to melt, as is the case with other plastic materials. There are efforts to separate the insulating materials involved in this material for recycling; thus reducing the negative effects resulting from cable manufacturing on the environment.

Through our discussion about what XLPE material is and what its advantages are, we can say that cables made from XLPE material are the best choice in renewable energy applications, such as: wind farms and solar energy, and floating wind stations, and there are many efforts being made to develop these cables to obtain better operational efficiency.