In cable manufacturing, the selection of insulation materials directly affects product performance, service life, and operational safety. The most commonly used insulation materials today include Polyvinyl Chloride (PVC), Polyethylene (PE), and Cross-linked Polyethylene (XLPE). Due to their distinct molecular structures and material properties, each is suited to different application scenarios.
1. Polyvinyl Chloride (PVC) Insulation
PVC is one of the most widely used cable insulation materials, known for its good mechanical strength, ease of processing, and excellent resistance to acids and alkalis. By incorporating flame retardant additives into its formulation, PVC insulation can achieve effective flame-retardant performance, making it suitable for general-purpose wires and cables.
Depending on hardness, flexible PVC is mainly used for insulation layers, while rigid PVC is commonly applied as cable sheathing. It should be noted that the long-term permissible operating temperature (conductor temperature) of PVC-insulated cables is typically 70 °C, and PVC may generate relatively dense smoke when exposed to fire.
2. Polyethylene (PE) Insulation
PE insulation is characterized by its outstanding electrical properties, including low dielectric constant, low dielectric loss, and high volume resistivity, making it particularly suitable for high-frequency signal transmission. In addition, PE exhibits excellent low-temperature performance and chemical stability.
PE-insulated cables are widely used in data communication cables, coaxial cables, and low- to medium-voltage power cables. The long-term permissible operating temperature (conductor temperature) of PE insulation is generally 70 °C.
3. Cross-linked Polyethylene (XLPE) Insulation
XLPE is a thermosetting material produced by chemically or physically cross-linking the linear molecular structure of PE into a three-dimensional network. This cross-linking process results in a significant improvement in material performance.
XLPE insulation offers:
A long-term permissible operating temperature increased to 90 °C
A short-circuit temperature resistance of up to 250 °C
Enhanced mechanical strength and improved resistance to environmental stress cracking
At the same time, XLPE retains the excellent electrical properties of PE. As a result, XLPE has become the preferred insulation material for medium- and high-voltage power cables, new energy cables, and industrial applications with demanding operating conditions.
4. Application Selection Guide
PVC-insulated cables: Economical and practical, suitable for indoor building wiring, general control cables, and other conventional dry environments.
PE-insulated cables: Superior electrical performance, ideal for data communication, signal transmission, and applications requiring stable capacitance characteristics.
XLPE-insulated cables: Comprehensive high performance, recommended for power transmission backbone networks, high-temperature environments, humid conditions, and industrial applications with extremely high reliability requirements.
In practical engineering applications, insulation material selection should consider operating temperature, environmental conditions, electrical parameters, mechanical requirements, and cost budget. With ongoing technological advancements and large-scale production, the overall cost-performance ratio of XLPE cables continues to improve, leading to their expanding range of applications.
About Us
As a professional cable material supplier, ONE WORLD has established complete production lines for PE, XLPE, and PVC insulation compounds, supported by advanced testing equipment such as Melt Flow Rate Testers, Hot Set / Heat Elongation Testers, and High-Voltage Breakdown Test Systems, providing a solid hardware foundation for product quality assurance.
We have implemented a strict, full-process quality management system covering raw material selection, production control, and final product inspection. Through precise gravimetric feeding and real-time online monitoring systems, we ensure consistency and stability across all key performance parameters. All products are packed using moisture-proof aluminum-plastic vacuum packaging to maintain material integrity during storage and transportation.
Our insulation materials strictly comply with GB/T 15065 and other relevant national standards. We are committed to delivering reliable, safe, and high-performance cable material solutions for power transmission, renewable energy generation, communication engineering, and a wide range of industrial applications.
Post time: Jan-30-2026