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Silane XLPE Compound of Sioplas Method for Aerial Wire and Cable up to 10kV
Warm Water Crosslinkable Polyethylene Insulation Compound for 10kV Aerial Cables – Silane Crosslinking XLPE Material
Warm water crosslinkable polyethylene insulation compound consisting of Compound A and Compound B. Features excellent extrusion performance, stable physical and chemical properties. Ideal for 10kV and below aerial cable insulation with maximum working temperature of 90°C. Compatible with loss-in-weight feeder systems to ensure precise component ratio control.
This warm water crosslinkable polyethylene insulation compound is a two-component silane crosslinking system specifically developed for manufacturing high-performance XLPE (cross-linked polyethylene) insulated cables. The material is ideal for overhead power cables rated at 10kV and below, offering a balance of excellent extrusion characteristics, thermal stability, and electrical insulation properties.
The compound consists of two separate components:
Compound A – Manufactured from high-quality polyethylene resin and imported silane coupling agent, providing the base polymer matrix for crosslinking.
Compound B – Made from organotin catalysts and antioxidant agents, which initiate and accelerate the crosslinking reaction when mixed with Compound A.
The manufacturing process uses a loss-in-weight feeder system, which ensures stable and precise control of the component ratio during extrusion. This level of accuracy helps to achieve consistent crosslinking density, uniform material properties, and reliable cable performance.
Unlike traditional XLPE compounds that require continuous vulcanization (CV) lines with high-pressure steam, this silane crosslinkable compound cures in warm water. This significantly reduces energy consumption, equipment costs, and manufacturing complexity, making it an economical choice for medium and small-scale cable producers.
Excellent extrusion performance – Smooth, consistent output on standard extruders
Smooth cable surface finish – Reduces electrical stress points
Stable physical and chemical indices – Batch-to-batch consistency ensures reliable quality
High crosslinking degree – Achieves ≥65% gel content per IEC 60502
Good thermal aging resistance – Suitable for long-term operation at elevated temperatures
Compound A + Compound B provide controlled and reliable crosslinking
Compatible with standard one-step or two-step silane crosslinking processes
Allows flexible production scheduling (compounds can be stored separately)
Smooth and consistent output on standard single-screw extruders
No need for specialized screw designs or equipment modifications
Reduces scrap rate and material waste during production startup
Batch-to-batch consistency ensures reliable cable quality
Tight control of melt flow index, density, and crosslinking behavior
Meets international standards for XLPE insulation materials
Maintains precise mixing ratio (typically 95:5 or 92:8 Compound A to Compound B)
Prevents under-crosslinking or over-crosslinking caused by ratio errors
Compatible with most gravimetric and volumetric feeder systems
Simple and energy-efficient crosslinking process
Curing conditions: typically 70°C to 90°C warm water for 4 to 8 hours
Eliminates need for high-pressure steam vulcanization lines
Reduces capital investment and operational costs
Suitable for long-term operation at elevated temperatures (up to 90°C continuous)
Maintains mechanical and electrical properties after thermal aging (e.g., 135°C for 168 hours per IEC 60811)
Resists thermal oxidative degradation due to built-in antioxidant system
No hazardous byproducts released during crosslinking
Lower energy consumption compared to steam curing
Reduced fire risk during production (no high-pressure steam)
This insulation compound is specifically designed for:
10kV and below aerial cable insulation (overhead insulated cables)
Maximum continuous working temperature: 90°C (conductor temperature)
Maximum short-circuit temperature: 250°C (for up to 5 seconds)
ABC (Aerial Bundled Cables) for overhead distribution
Single-core and multi-core aerial cables
Overhead service drop cables
Rural electrification cables
Urban power distribution cables
The above temperature rating is for reference only. Actual application should be verified according to cable design, operating conditions, and relevant national or international standards (e.g., IEC 60502, GB/T 14049).
To maintain product quality and performance, please follow these storage guidelines:
| Condition | Requirement |
|---|---|
| Storage temperature | Keep at room temperature (15°C to 30°C recommended) |
| Environment | Clean, dry, and well ventilated |
| Best before date | Use within six months from production date |
| After mixing Compound A and B | Use within 8 hours (to prevent premature crosslinking) |
| After opening Compound A | Use within 24 hours (seal tightly after each use) |
Store away from direct sunlight, heat sources, and moisture
Keep bags sealed until ready for use
Do not store near solvents, acids, or alkalis
Proper storage prevents:
Moisture absorption (which can cause voids and poor crosslinking)
Premature crosslinking (which can lead to scorching during extrusion)
Degradation of silane coupling agent and catalyst activity
| Component | Weight per bag | Packaging material |
|---|---|---|
| Compound A | 23.75 kg | Moisture-resistant aluminum laminated bag + outer composite paper bag |
| Compound B | 1.25 kg | Moisture-resistant aluminum laminated bag + outer composite paper bag |
| Total package weight | 25 kg per combined unit (A + B) |
Aluminum laminated inner layer provides excellent moisture barrier protection
Composite paper outer bag ensures mechanical strength during transport and handling
Easy-to-open design for efficient production line feeding
Clear labeling with batch number, production date, and component identification
500 kg or 1000 kg bulk bags (FIBC)
Custom packaging for large-scale production lines
| Benefit | Description |
|---|---|
| Energy saving | Warm water curing eliminates energy-intensive steam vulcanization lines |
| High crosslinking degree | Achieves ≥65% gel content per IEC 60502 (typical range: 65–80%) |
| Good heat deformation resistance | Suitable for continuous 90°C operation with low deformation under load |
| Smooth cable surface | Reduces risk of electrical stress points and partial discharge |
| Compatible with standard extruders | No expensive modifications required; works with L/D 20:1 to 25:1 extruders |
| Low scrap rate | Consistent extrusion reduces material waste during startup and changeovers |
| Long shelf life | Six-month shelf life when properly stored (unmixed components) |
| Environmentally friendly | No hazardous byproducts; lower carbon footprint compared to steam-cured XLPE |
| Parameter | Recommended Value |
|---|---|
| Extruder temperature profile | 150°C – 190°C (gradual increase from feed zone to die) |
| Die temperature | 180°C – 200°C |
| Screw speed | 30 – 80 rpm (depending on extruder size) |
| Cooling method | Water trough (ambient temperature) |
| Curing method | Warm water bath: 70°C – 90°C for 4 – 8 hours |
| Crosslinking degree verification | Measure gel content per IEC 60502 after curing |
Note: Actual processing parameters may vary depending on extruder type, screw design, and cable construction. Optimization trials are recommended.
Each batch of compound is tested to ensure compliance with the following typical specifications:
| Property | Test Method | Typical Value |
|---|---|---|
| Density (Compound A) | ASTM D1505 | 0.920 – 0.925 g/cm³ |
| Melt flow index (190°C/2.16kg) | ASTM D1238 | 1.5 – 3.5 g/10 min |
| Tensile strength (before aging) | IEC 60811 | ≥ 13.5 MPa |
| Elongation at break (before aging) | IEC 60811 | ≥ 350% |
| Tensile strength retention (after aging) | IEC 60811 | ≥ 80% |
| Elongation retention (after aging) | IEC 60811 | ≥ 80% |
| Gel content | IEC 60502 | ≥ 65% |
| Volume resistivity | IEC 60093 | ≥ 1 × 10¹⁵ Ω·cm |
| Dielectric strength | IEC 60243 | ≥ 25 kV/mm |
