Electrical and Mechanical Properties of new Recyclable Power Cable Insulation Materials based upon Polyethylene Blends

Abstract

Chemically crosslinked polyethylene (XLPE) has been used as electrical insulation for power cables since the 1970s due to its favourable combination of electrical and mechanical properties. However, as the electrical engineering community has become increasingly aware of the life cycle environmental impacts, XLPE has come under scrutiny for its lack of recyclability and the high process energies used in its manufacture. Although technologies are being developed to facilitate the re-use of XLPE at the end of its initial service life, the use of this material is inferior to fully recyclable and low process energy alternatives. In this investigation, we concentrated on the use of binary blends of linear and branched polyethylene (LPE / BPE) as potential replacement materials for XLPE, since such systems have the potential to combine comparable mechanical properties and enhanced breakdown strength with good recyclability. We compare the thin film AC ramp breakdown behaviour of blends as a function of temperature up to 97 oC. These consist of the same BPE in virgin and crosslinked states and in a blend with 20wt% LPE. These data are augmented with dynamic mechanical analysis. In concert, these data indicate that with appropriate morphological control the blended thermoplastic material exhibits superior properties to XLPE under conventional operating conditions and may even be suitable for higher temperature operation than XLPE. The paper will discuss the importance of polymer blending and blend physical properties in the context of the process requirements and the implications for cable manufacture and on cable electrical and environmental performance in comparison with XLPE.

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ORCID for A.S. Vaughan: orcid.org/0000-0002-0535-513X

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