Selection and Application of XLPO and XLPE Compounds
Tired of cables failing under heat, oil splash, or mechanical stress? The right compound makes all the difference—especially in high-risk industrial systems.
Cross-linked polyolefin (XLPO) and cross-linked polyethylene (XLPE) offer unique strengths. This guide explains where each performs best and helps you choose based on your voltage, flame class, and environmental exposure.
Typical Applications of XLPO vs. XLPE Cable Compounds
Still unsure where XLPO or XLPE fits? Real-world cable examples clarify why each compound wins in different layers or environments.
XLPO Compound Applications
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Automotive Harnesses
XLPO jackets handle 125 °C continuous. They resist oils (ASTM D543), last 100,000 bends, and meet ISO 6722 smoke specs with LSZH grades.
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Solar Cables
XLPO jackets survive –40 to +120 °C and UV per 1,000 kWh xenon arc. TÜV 2 PfG 1169 and IEC 62930 LSZH specs are met with silane-cured XLPO.
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Railway/Subway LSZH Jackets
Meets EN 45545 HL2/HL3 (R15/R16), OI > 28%, smoke density <150%. Resists oil and abrasion per EN 50363-10.
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Appliance Wiring
UL 758 AWM 1015 styles use XLPO at 105–125 °C. Avoids plasticizer migration. Keeps softness over years.
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Heat-Shrink Tubing
EB-cured XLPO enables tight shrink at 120 °C. UL VW-1 flame grade. Used in sensor, battery, and chassis harnesses.
XLPE Compound Applications
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MV/HV Power Cable Insulation
XLPE (PE-Xa) cured with peroxide handles 90 °C continuous, 250 °C short fault. Resists water treeing per IEC 60811. Rated for 30–500 kV lines.
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Building Wiring Semicon Screens
XLPE compounds used for semiconductive layers in MV grids. Tuned to 30% gel content, 10 Ω·cm resistivity.
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Subsea and Mining Cables
XLPE insulation resists water, oil, and abrasion. Withstands 20,000 h in oil at rated conditions.
Application Overview Table
| Sector/Application | Preferred Compound | Key Advantage |
|---|---|---|
| Auto harness | XLPO | Flex + oil + low smoke |
| PV solar cable | XLPO | UV + temp cycling + LSZH |
| Rail/transit jacket | XLPO | Low smoke, zero halogen |
| Home appliances | XLPO | Thin-wall + heat + flexibility |
| Heat-shrink tubes | XLPO (EB-cured) | Flame + shrink + tight fit |
| MV/HV insulation | XLPE | Water tree resistance + dielectric |
| MV field grading screen | XLPE | Semicon + process consistency |
| Mining/subsea cable | XLPE | Deep pressure + chemical resistance |
How to Choose Between XLPO and XLPE Based on Cable Requirements
Worried about flame standards or voltage grade? Use this selection guide to match your cable spec to compound capability.
1. Voltage and Dielectric Requirements
- XLPO: Suitable for LV cables up to 1 kV (jackets or insulation at 125–150 °C).
- XLPE: Ideal for MV (1–35 kV) and HV (up to 500 kV), with ≥70% gel content for electrical purity.
2. Operating Temperature and Thermal Rating
- XLPO: Rated up to 125–150 °C continuous; short peaks to 250 °C.
- XLPE: Standard 90 °C continuous; 250 °C fault.
Choose XLPO in harsh ambient or confined locations. XLPE fits where voltage stress dominates, and ambient stays under 90 °C.
3. Flame and Smoke Regulations
- XLPO: Meets IEC 60332, IEC 61034, IEC 60754 (LSZH compliant).
- XLPE: Requires FR additives; not halogen-free unless jacketed.
Use XLPO where CPR Euroclass, NFPA 130, or EN 45545 applies. XLPE suits basic flame compliance (VW-1) in industrial or outdoor power.
4. Chemical and Mechanical Resistance
- XLPO: Excellent oil, acid, and abrasion resistance (ASTM D543).
- XLPE: Good baseline resistance, but jackets may need TPU or PVC in oil zones.
Use XLPO for machine cables, EV battery packs, or oil-field gear. XLPE is more suited to buried or shielded use.
5. Processing and Line Compatibility
| Method | XLPO | XLPE |
|---|---|---|
| Cure Type | Silane / EB / Peroxide | Mostly Peroxide |
| Cure Control | Needs humidity / oven | Fast, known recipe |
| Line Speed | Slower | High throughput |
| Extruder Setup | May need jacket mod | Standard insulation lines |
Match material to your plant’s capabilities. XLPE wins in speed and insulation lines; XLPO fits when jacket control matters more than speed.
6. Cost and Lifecycle Economics
- XLPO: +10–30% per kg vs. XLPE, but fewer maintenance events and fire-related downtime.
- XLPE: Lower resin cost, mature supply, and faster line rates—but potential for more field repairs in jacket roles.
Selection Criteria Summary
| Parameter | XLPO Advantage | XLPE Advantage |
|---|---|---|
| Max Temperature | 125–150 °C continuous | 90 °C continuous |
| Dielectric Use | Jacket-level insulation (≤1 kV) | Full insulation at 1–500 kV |
| Flame Code Compliance | LSZH ready, B2ca/HL3 compliant | VW-1/FR with smoke trade-off |
| UV / Oil Resistance | Strong with stabilizers | Moderate, needs jacket aid |
| Line Integration | Jacket lines with silane / EB options | Fast peroxide insulation lines |
| Lifecycle Cost | Higher upfront, lower fire loss risk | Lower upfront, higher over time |
Conclusion
Choosing between XLPO and XLPE depends on your cable’s job:
- For jackets in high-heat, flex, or regulated areas, XLPO offers cleaner burn, better flex, and LSZH compliance.
- For power cable insulation from 1 to 500 kV, XLPE offers proven performance, faster processing, and dielectric stability.
📌 Need help selecting or formulating the right XLPO or XLPE compound?
We supply peroxide-, silane-, and EB-cured compounds tailored to automotive, solar, building, MV, and specialty cable markets.