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1. Why Electric Cable Compounds Matter in Modern Infrastructure
In modern infrastructure, cables are not just “conductors.” The external protection and insulation materials — Electric Cable Compounds — determine whether systems can operate safely and reliably over the long term. Whether in power transmission, data communication, rail transit, or new energy systems, Electric Cable Compounds play a decisive role in:
FSY/ZH-90 90℃ PVC Flame Retardant Anti-Rodent Anti-Termite Soft Sheath Plastic
1.1 Safety Assurance
- Insulation performance: High-quality Electric Cable Compounds have excellent dielectric strength to prevent short circuits and leakage.
- Flame retardancy: In a fire scenario, superior materials can slow flame spread and reduce the release of harmful smoke.
| Performance Indicator | Standard PVC Compound | Low Smoke Zero Halogen Compound |
|---|---|---|
| Dielectric Strength (kV/mm) | 12–14 | 14–16 |
| Flame Retardancy (UL94) | V-2 | V-0 |
| Smoke Density (ASTM E662) | High | Low |
1.2 Environmental Adaptability
Formulations can be optimized for specific climates and environments — heat resistance, cold resistance, UV resistance, salt spray resistance — ensuring performance even in harsh conditions.
| Condition | Standard Compound Range | Special Compound Range |
|---|---|---|
| Temperature Range (°C) | -10 ~ 70 | -40 ~ 125 |
| UV Resistance | Medium | High |
| Salt Spray Resistance | < 48 hours | > 500 hours |
1.3 Service Life & Maintenance Cost
- Ordinary materials: ~10–15 years (indoor)
- Modified polymers: 25–30 years (outdoor harsh environments)
1.4 Impact on Overall Infrastructure Performance
- Cable failure can cause massive outages or communication breakdowns; material quality directly impacts risk levels.
- In smart grids and high-speed data systems, high-grade Electric Cable Compounds maintain low dielectric loss, improving efficiency.
2. Understanding the 'Heart' of Cables: A Deep Dive into Electric Cable Compounds
Within a cable's complex structure, Electric Cable Compounds act like the “heart,” providing insulation, protection, flexibility, and environmental resistance.
2.1 Definition and Functions
Electric Cable Compounds are formulated from polymer bases (PVC, PE, rubber-based materials) and functional additives (flame retardants, plasticizers, antioxidants, UV stabilizers). Main functions:
- Insulation Layer: Prevents current leakage and ensures safety.
- Sheath Layer: Shields conductors from mechanical, chemical, and environmental damage.
- Filling & Separator: Maintains structure stability and reduces mechanical stress.
2.2 Material Type Performance Comparison
| Performance Indicator | Thermoplastic PVC | Cross-linked PE (XLPE) | Ethylene-Propylene Rubber (EPR) |
|---|---|---|---|
| Operating Temp (°C) | -10 ~ 70 | -40 ~ 90 | -40 ~ 90 |
| Dielectric Strength (kV/mm) | 12–14 | 18–22 | 15–18 |
| Tensile Strength (MPa) | 15–20 | 18–22 | 8–12 |
| Flame Retardancy (UL94) | V-0 / V-2 | Needs additive | Needs additive |
| Dielectric Constant (50Hz) | 3.0–3.5 | 2.2–2.4 | 2.5–2.7 |
| UV Resistance | Medium | High | High |
2.3 Matching Material to Application
- High temperature/high voltage → XLPE compounds.
- High flexibility → EPR compounds.
- Cost-performance balance → PVC compounds.
3. Types of Electric Cable Compounds and Their Functions
Electric Cable Compounds fall into two main categories: Thermoplastic and Thermosetting, each serving different roles.
3.1 Thermoplastic Compounds
- PVC: Good overall performance, flame retardancy, cost-effective.
- PE: Excellent dielectric properties, ideal for high-frequency signals.
3.2 Thermosetting Compounds
- XLPE: High temperature resistance, superior insulation, suitable for high-voltage cables.
- EPR: Excellent flexibility, water and ozone resistance.
3.3 Common Compound Performance Comparison
| Material Type | Category | Temp Range (°C) | Dielectric Strength (kV/mm) | Flame Retardancy (UL94) | Flexibility | Typical Application |
|---|---|---|---|---|---|---|
| PVC Compound | Thermoplastic | -10 ~ 70 | 12–14 | V-0 / V-2 | Medium | Building wiring, low-voltage |
| PE Compound | Thermoplastic | -60 ~ 80 | 18–20 | Needs additive | Medium | HF/data/communication |
| XLPE Compound | Thermosetting | -40 ~ 90 | 18–22 | Needs additive | Low | High-voltage, submarine |
| EPR Compound | Thermosetting | -40 ~ 90 | 15–18 | Needs additive | High | Mobile, rail, marine |
4. Key Performance Factors of Electric Cable Compounds
4.1 Electrical Properties
| Indicator | Unit | PVC | XLPE | EPR |
|---|---|---|---|---|
| Dielectric Strength | kV/mm | 12–14 | 18–22 | 15–18 |
| Dielectric Constant (50Hz) | — | 3.0–3.5 | 2.2–2.4 | 2.5–2.7 |
| Volume Resistivity (20°C) | Ω·cm | ≥1×10¹³ | ≥1×10¹⁴ | ≥1×10¹³ |
4.2 Mechanical Properties
| Indicator | Unit | PVC | XLPE | EPR |
|---|---|---|---|---|
| Tensile Strength | MPa | 15–20 | 18–22 | 8–12 |
| Elongation at Break | % | 150–200 | 300–500 | 250–400 |
| Abrasion Resistance | — | Medium | High | High |
4.3 Flame Retardancy & Environmental Safety
| Indicator | Unit | Standard PVC | Low Smoke Zero Halogen |
|---|---|---|---|
| Flame Retardancy (UL94) | — | V-2 / V-0 | V-0 |
| Smoke Density (ASTM E662) | — | High | Low |
| Halogen Content | % | 15–25 | <0.5 |
4.4 Environmental Resistance
| Indicator | Unit | PVC | XLPE | EPR |
|---|---|---|---|---|
| Temp Range | °C | -10 ~ 70 | -40 ~ 90 | -40 ~ 90 |
5. How to Choose the Right Electric Cable Compounds
Selecting the right Electric Cable Compounds ensures cable performance, service life, and safety.
5.1 Define Application Environment and Requirements
- Temperature: Select heat/cold-resistant materials for extreme conditions.
- Mechanical Stress: Choose high elongation and abrasion resistance for frequent bending.
- Flame Retardancy & Environmental: For public facilities and transit systems, choose low smoke, halogen-free, flame-retardant materials.
- Electrical: High voltage or high-frequency systems require high dielectric strength and low dielectric constant.
5.2 Performance Comparison
| Material Type | Temp Range (°C) | Dielectric Strength (kV/mm) | Flame Retardancy (UL94) | Elongation (%) | Typical Use |
|---|---|---|---|---|---|
| PVC Compound | -10 ~ 70 | 12–14 | V-0 / V-2 | 150–200 | Indoor wiring, low-voltage |
| XLPE Compound | -40 ~ 90 | 18–22 | Needs additive | 300–500 | High-voltage, underground cables |
| EPR Compound | -40 ~ 90 | 15–18 | Needs additive | 250–400 | Mobile, marine, rail |
| Low Smoke Zero Halogen | -20 ~ 90 | 14–16 | V-0 | 150–250 | Public facilities, tunnels |
5.3 Production Capability & Quality Assurance
Hangzhou Meilin New Materials Technology Co., Ltd., established in 1994, focuses on high-performance Electric Cable Compounds:
- Scale: Two production sites, 30,000+ m² building area, 18 advanced automated lines.
- Expertise: 5 senior engineers, over 30% technical management staff with college degrees or above.
- Capacity: 2022 output value exceeded RMB 500 million; new factory operational since 2021.
- Quality Control: Comprehensive testing and stable formulations meeting international standards.
5.4 Decision Process
- Requirement Analysis
- Parameter Matching
- Sample Verification
- Mass Production with quality consistency
5.5 Recommendation
When selecting Electric Cable Compounds, balance cost, durability, compliance, and supply stability. Manufacturers like Hangzhou Meilin New Materials Technology Co., Ltd. can provide comprehensive solutions to ensure cable safety and reliability across diverse applications.
