Cross linked cable refers to a kind of cable that uses physical or chemical methods to make longitudinal or transverse cross-linking between polymer molecules, so as to improve the heat resistance, cold resistance, flame retardancy, mechanical strength, aging resistance and electrical properties of the cable’s insulating medium and sheath material.

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I. Application areas of cross linked cables:

Aerospace field: in aerospace equipment, cross-linked cables play an important role. It is widely used in satellites, space shuttles, rockets and other equipment due to its high temperature resistance, good fire resistance and strong radiation resistance. In these equipments, cross-linked cables are not only used to transmit data and signals, but also undertake the key task of transmitting high-voltage electrical energy.

Rail transportation field: With the rapid development of urban rail transportation, the performance requirements for cables are increasing. With its good fire resistance and excellent mechanical properties, cross-linked cable has become the preferred material for power transmission and control cables in urban rail transit. Cross-linked cables play an indispensable role in the drive system, signaling system, control system and so on.

Industrial field: In industrial production, cross-linked power cables are widely used in power transmission, distribution and power supply systems due to their characteristics of high temperature resistance, fire resistance, abrasion resistance and explosion resistance. Whether it is high-speed railroad, automobile manufacturing, shipbuilding or aircraft manufacturing and other industries, cross-linked cable is an important material to ensure production safety and stability.

Construction field: In the construction industry, cross-linked power cables are also widely used. Hospitals, airports, shopping malls, gymnasiums, schools and a large number of other places that use electricity need to use cross-linked power cables. In addition, due to its low power loss and excellent energy-saving performance, cross-linked cable is gradually becoming an important choice for green buildings.

Domestic electricity field: Cross-linked power cables also play an important role in domestic electricity consumption. It can be used for air conditioning power lines, lamps and lanterns wires, water heater power lines, etc., which not only ensures the electrical safety, but also makes the household electrical power more energy-saving.

Second, the production of cross-linked cable process

At present, the production of cross-linked cable process is mainly divided into three categories: peroxide chemical crosslinking, silane chemical crosslinking and irradiation crosslinking.

1, inert gas crosslinking (dry chemical crosslinking)
Inert gas cross-linking, that is, dry chemical cross-linking, using polyethylene insulation materials involved in peroxide crosslinking agent. After the extrusion of the conductor shield, insulation layer, insulation shield, through the high temperature, high pressure nitrogen sealed crosslinking tube to complete the crosslinking process. The method of heat transfer media for nitrogen, suitable for cross-linked polyethylene electrical function excellent, production planning up to 500KV level of high-voltage cable.

Common inert gas cross-linked cables are: YJV series, YJY series, flame retardant cross-linked series.

It should be noted that you need to check the technical specifications of the cable or consult the manufacturer to understand the specific crosslinking and performance characteristics, rather than relying solely on the model.

2、 Silane chemical crosslinking (warm water crosslinking)
Silane chemical cross-linking, i.e., warm water cross-linking, using polyethylene insulation materials involved in silane cross-linking agent. After the extrusion of the heterogeneous shielding layer, insulation layer, insulation shielding layer, the insulated wire core that has been cooled and loaded into the disk is immersed in 85-95 ℃ hot water for hydrolysis crosslinking. As wet crosslinking affects the water content in the insulation layer, the general maximum voltage level is only up to 10kV.

If the steam steamer crosslinking, the finished wire into the warehouse or steamer at an ambient temperature of 90 ℃ or more than 4-6 hours or so can be crosslinked.

Low-smoke halogen-free wires are made of silane self-crosslinking low-smoke halogen-free polyolefin cable material, which can be naturally crosslinked at natural ambient temperatures.

The following are some common models of silane chemically cross-linked cables:

Low-voltage silane cross-linked cable:

1) YJV: cross-linked polyethylene insulated PVC sheathed power cable

2) YJY: cross-linked polyethylene insulated polyethylene sheathed power cable

Medium voltage silane cross-linked cable:

(1) YJV22: cross-linked polyethylene insulated steel tape armored PVC sheathed power cable

(2) YJY23: cross-linked polyethylene insulated steel tape armored polyethylene sheathed power cable

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Flame retardant silane cross-linked cable:

1）ZR-YJV：Flame-retardant cross-linked polyethylene insulated PVC sheathed power cable

2）ZR-YJY：Flame-retardant cross-linked polyethylene insulated polyethylene sheathed power cable

Fire-resistant silane cross-linked cable:

1）NH-YJV：Fire-resistant cross-linked polyethylene insulated PVC sheathed power cable

2）NH-YJY：Fire-resistant cross-linked polyethylene insulated polyethylene sheathed power cable

Low-smoke halogen-free silane cross-linked cable:

1）WDZ-YJY：Low-smoke-halogen-resistant cross-linked polyethylene insulated polyethylene sheathed power cable

2）WDZ-YJV：Low-smoke-halogen free flame retardant cross-linked polyethylene insulated PVC sheathed power cable

Aluminum alloy conductor silane cross-linked cable:

1）YJLHV：Aluminum alloy conductor cross-linked polyethylene insulated PVC sheathed power cable

(2) YJLHY: Aluminum alloy conductor cross-linked polyethylene insulated polyethylene sheathed power cable

3、Irradiation crosslinking (physical crosslinking)
Irradiation cross-linking, i.e. physical cross-linking, uses modified polyethylene insulating material. In the conductor shielding layer, insulation layer, insulation shielding layer after the extrusion, the cooled insulated wire core uniformly through the high-energy electron gas pedal irradiation scanning window to complete the crosslinking process.

Irradiation crosslinking cable does not participate in the crosslinking agent, crosslinking by high-energy electron gas pedal generated by the high-energy electron beam effectively penetrate the insulation layer, the energy conversion to produce crosslinking reaction.

Due to the high and uniform electron energy through the insulating layer, the formation of crosslink bonding high energy, good stability, showing excellent heat resistance.

However, due to the limitations of the gas pedal energy level, generally does not exceed 3.0Mev electron beam effective penetration thickness of 10mm or less, taking into account the geometric factors, the voltage level of the production cable can only reach 10kV, the advantage of 6kV or less.

Common irradiated cross-linked cable models include:

(1) WDZ-BYJ(F): irradiated cross-linked low smoke halogen free flame retardant polyethylene insulated cable.

(2) FZ-KYJV: irradiated cross-linked polyethylene insulated control cable.

(3）WDZ-KYJ(F)：irradiated crosslinked low smoke halogen-free flame retardant control cable.

(4）WDZ-YJ(F)E：irradiated crosslinked low smoke halogen free flame retardant polyethylene insulated power cable.

High quality cross-linked polyethylene cable supplier TST CABLES
TST CABLES As a professional manufacturer and supplier of high quality cross-linked polyethylene cables, we are committed to producing high quality cross-linked polyethylene cables, also widely known as XLPE cables. We adopt advanced production process to ensure that each cross-linked polyethylene cable has excellent electrical performance and durability to meet the diversified needs of our customers. If you have needs and questions about cross-linked polyethylene cables welcome to contact us by .

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XLPE cable benefits

Cross-linked polyethylene (PEX or XLPE) has been around for quite some time. The first cross-linking methods emerged in the s and practices have continued to evolve since, with other processes being developed throughout the years. Cross-linking is a very intricate process. XLPE raw material powder is formed and processed into sturdy, durable end products, usually formed into cylindrical shapes that can be used for electric industry.



There are many benefits to cross-linked polyethylene. Some include:

. Works with a variety of voltage ranges 600V to 35kV
. Provides mechanical protection
. Can withstand extreme pressure
. Resists underground damage
. Weather-resistant
. Thermal resistance
. Permits high conductor operating temperatures
. Reduces short circuit and overload levels
. Is more cost effective than traditional solutions
. Flexible
. Moisture resistant

Cross-linked polyethylene can be useful in the electric industry. At present, most of the high-voltage cables have been used for cross-linked polyethylene insulated cross-linked cables, The most commonly used material is cross-linked polyethylene (XLPE).  Cross-linked cable is short for cross-linked polyethylene (XLPE)  insulated cable. Cross-linked cables are suitable for transmission and distribution lines with power frequency AC voltage of 500KV and below.

Processing engineering is the process of using polyethylene (PE) material with linear molecular structure through a specific processing method to form a cross-linked polyethylene with a body-shaped network split line structure. The long-term allowable working temperature is increased from 70°C to 90°C (or higher), and the short-circuit allowable temperature is mainly increased from 140°C to 250°C (or higher). While maintaining its original excellent electrical performance, it has greatly improved Actual performance.


XLPE cable characteristics

The aging life of cable insulation material mainly depends on its thermal aging life. It is determined by the speed of thermal oxygen oxidation, thermal cracking, thermal oxidative cracking, polycondensation and other chemical reactions that occur in the insulating material under heat. Therefore, the insulating material The thermal aging life of the cable directly affects the service life of the cable. According to the chemical reaction kinetics derivation and the artificial accelerated thermal aging test (20-30 years), the long-term allowable working temperature of the irradiated cross-linked cable is:
1. If the power cable 0.6/1KV(LV Cable)  is deduced according to the rated working temperature of 105 degrees, its thermal aging life exceeds 60 years.
If deduced according to the rated operating temperature of 90 degrees, its thermal aging life exceeds 100 years.

When overhead insulated cables are laid in the open air, the environmental and radiation resistance of insulating materials is more important. Irradiation cross-linked insulating materials have to undergo irradiation processing, and they have good radiation resistance. The radiation dose applied in the cross-linking production process leaves a large safety margin from the destruction dose.

Between XLPE and PVC as used in cable insulation

XLPE is suitable for voltage ranges from low to extra high voltage, surpassing other insulation materials such as PVC, Ethylene Propylene Rubber (EPR) and silicone rubbers. Cross-linking the polyethylene also enhances the chemical and oil resistance at elevated temperatures and makes it suitable for use as a Low Smoke Zero Halogen material.   

The mechanical properties of the XLPE are superior to many other insulations, offering greater tensile strength, elongation and impact resistances. The addition of carbon black can be used to further enhance hot deformation and cut through resistance. The XLPE insulation will not melt or drip, even at the temperatures of soldering irons, and it has increased flow resistance and improved ageing characteristics.

Improved water-tree resistance is another benefit of XLPE insulation for LV cables and MV cables over PE insulations. Water treeing is a defect which is the result of imperfections in the insulation where fracture lines occur and grow in the direction of the electric field, increasing with electrical stress.