XLPO Compound vs XLPE Compound
Worried your cable jacket will deform or drip under overload? The difference between XLPO and XLPE compounds determines how your cables perform under stress, heat, and fire.
XLPO (cross-linked polyolefin) compounds are known for clean burning, chemical resistance, and high heat tolerance—ideal for jackets and tubing.
XLPE (cross-linked polyethylene) compounds dominate power cable insulation due to their dielectric strength and water tree resistance.
In this article, I’ll break down their structure, compare performance, and help you decide which compound is better for your application.
What Are XLPO and XLPE Compounds?
Both XLPO and XLPE are thermoset polymer systems formed by cross-linking thermoplastic base resins. The difference lies in the base material and processing method.
Basic Definitions
- XLPO: Cross-linked polyolefin—typically based on PE or PP. Cured by silane, peroxide, or EB (electron beam).
- XLPE: Cross-linked polyethylene—based only on PE, usually cured by peroxide or silane.
Both compounds resist melt flow and improve thermal, mechanical, and chemical stability.
| Compound | Base Resin | Cross-Linking Method | Common Use |
|---|---|---|---|
| XLPO | PE, PP | Silane, Peroxide, EB | Cable jackets, harnesses, tubing |
| XLPE | LDPE, HDPE | Peroxide, Silane | Power cable insulation |
Key Differences Between XLPO and XLPE in Cable Applications
Wondering which material fits your cable layer—jacket or insulation? Their difference shows in temperature rating, flame behavior, processing, and dielectric use.
1. Thermal Performance
- XLPO: 125–150 °C continuous, up to 250 °C short-term
- XLPE: 90 °C continuous, 250 °C short-circuit (standard for MV/HV insulation)
XLPO maintains jacket shape and flexibility under flame exposure, whereas XLPE may soften before charring.
2. Mechanical Properties
- Tensile Strength: Both ~15 MPa
- Elongation at Break: XLPO >200%, XLPE ~200%
- Flex Life: XLPO > XLPE
- Abrasion Resistance: XLPO jackets outperform in rough installation routes
3. Flame and Smoke Behavior
- XLPO: Supports halogen-free LSZH systems with non-halogen fillers
- XLPE: Needs additional FR (often halogenated or phosphorus-based) to meet IEC 60332 or UL VW-1
XLPO is cleaner-burning and better for fire-restricted zones like public transport.
4. Processing and Extrusion
- XLPE: Well-optimized in existing peroxide cross-linking lines
- XLPO: May require silane curing setups, moisture control, or EB facilities
XLPE wins for insulation throughput. XLPO is better suited for jacket/tubing where compound accuracy is more critical than speed.
| Comparison Aspect | XLPO | XLPE |
|---|---|---|
| Continuous Temp Rating | 125–150 °C | 90 °C |
| Short-Term Temp | 250 °C | 250 °C |
| Halogen-Free? | Yes | Optional |
| Flexibility | High (jacket/tubing) | Moderate |
| Dielectric Strength | Medium | High (insulation use) |
| Fire Resistance | LSZH capable | Needs FR additives |
| Processing | Complex (silane, EB) | Simple (peroxide lines) |
Advantages and Limitations of XLPO vs. XLPE
Still torn between clean flame behavior and power system compatibility? Here's a direct breakdown by function and trade-off.
| Category | XLPO | XLPE |
|---|---|---|
| Heat Resistance | 125–150 °C continuous | 90 °C continuous |
| Dielectric Strength | Good for jackets | Excellent for MV/HV |
| Water Tree Resistance | Moderate | Excellent |
| Flame and Smoke | LSZH, halogen-free | Needs FR, may smoke |
| Flexibility | Excellent in jackets | Moderate |
| UV Resistance | High (with stabilizer) | Limited |
| Chemical Resistance | Oils, acids, alkalis | Good general resistance |
| Processing | Slower, precise | Faster, mature line setup |
| Cost Impact | Higher compounding cost | Lower base cost |
| Application | Jackets, tubing, auto harness | MV insulation, control cable |
In Summary:
- Choose XLPO for:
- Cable jackets in rail, auto, solar, appliance
- Where fire code requires LSZH
- Outdoor or corrosive environments
- High-flex areas
- Choose XLPE for:
- Medium/high-voltage power insulation
- Long-run extrusion lines
- Applications where dielectric and water treeing dominate
Conclusion: XLPO or XLPE—Which Is Better?
The right cable compound depends on your layer’s function and risk exposure.
- Use XLPO where you need heat resistance, mechanical durability, flame safety, and halogen-free compliance.
- Use XLPE where electrical insulation, water treeing, and cost-efficient extrusion are critical.
📌 Need help choosing or formulating XLPO or XLPE for your application?
We offer peroxide and silane cross-linked compounds tailored for jacket, insulation, and tubing.