Insulated cable—the core component for transmitting electrical energy in power systems.-Qinshan

Insulated cable—the core component for transmitting electrical energy in power systems.

May 14,2025

As the core component for transmitting electrical energy in power systems, the performance of insulated cables directly affects the safety and efficiency of power supply. The following will discuss... Insulating Materials: Performance Comparison, Application Scenarios, and Key Purchasing Considerations Analyze from four aspects:

I. Comparison of Characteristics of Mainstream Insulation Materials

Polyvinyl chloride (PVC) insulation

Feature High mechanical strength, oil and corrosion resistance, and low cost—but tends to soften at high temperatures (long-term operating temperature ≤70℃) and releases toxic gases when burned.
Applicable scenarios Scenarios that are cost-sensitive, such as low-voltage distribution systems, home renovation, and lighting circuits.

Cross-linked polyethylene (XLPE) insulation

Feature Excellent thermal stability (long-term operating temperature up to 90℃), low dielectric loss, chemical corrosion resistance, high mechanical strength, and current-carrying capacity approximately 25% higher than PVC.
Applicable scenarios High-voltage transmission, industrial power cables, petrochemicals, and other high-temperature, high-load environments.

Polyethylene (PE) insulation

Feature : Resistant to low temperatures (retains flexibility even at -60℃) and resistant to chemical corrosion, but has poor heat resistance (long-term operating temperature ≤70℃).
Applicable scenarios Scenarios with high requirements for low temperature or flexibility, such as communication cables, underground cables, and automotive wires.

Rubber insulation

Feature Good elasticity, wear resistance, and cold resistance (can withstand low temperatures down to -50℃), but relatively poor oil resistance.
Applicable scenarios Scenarios requiring frequent bending, such as mobile devices, power tools, and mining machinery.

Mineral Insulated (MI)

Feature Using magnesium oxide as the insulating layer, it boasts exceptional fire resistance (remaining effective for 3 hours at 1000℃), is halogen-free and non-toxic; however, it has high costs and poor flexibility.
Applicable scenarios Scenarios with stringent fire protection requirements, such as fire-fighting circuits in high-rise buildings, nuclear power plants, and tunnels.

II. Performance Comparison and Selection Logic

Heat resistance XLPE (90℃) > PVC/PE (70℃) > Rubber (-50℃ cold-resistant but poor heat resistance).
Carrying capacity XLPE > PVC > PE—under the same cross-sectional area, XLPE cables can carry higher currents.
Environmental friendliness Mineral-insulated, halogen-free, low-smoke cables—when XLPE or PE burns, the primary combustion products are water and carbon dioxide; in contrast, PVC combustion releases toxic gases.
Cost PVC < PE < XLPE < Rubber < Mineral Insulation.

III. Recommended Typical Application Scenarios

Household power distribution Prioritize PVC-insulated copper-core cables (such as BV wires), balancing cost and safety.
Industrial power For high-voltage applications, YJV (XLPE-insulated) cables are recommended due to their high-temperature resistance and large current-carrying capacity.
Data center Use low-smoke, halogen-free flame-retardant cables (such as WDZ-YJY) to reduce fire risks.
Extreme environment ：

High-temperature areas (such as metallurgical plants): Use high-temperature-resistant silicone rubber insulated cables.
Low-temperature environments (such as polar scientific expeditions): Use cables with PE or ethylene-propylene rubber insulation.
Fire protection system: Mandatory use of mineral-insulated cables (such as BTTZ).

IV. Key Considerations for Selection

Certification mark Check for CCC certification and ISO 9001 quality system certification to ensure compliance.
Visual inspection ：

Conductor: The copper core should be purplish-red, bright, and free of burrs; the aluminum core should be silvery white.
Insulation layer: Uniform thickness, free of bubbles and cracks; PVC insulation layer thickness ≥ 0.8 mm (for 1.5 mm² cables).

Specification matching ：

Select the cross-sectional area based on the load current (e.g., for a 10A current, choose a 1.5 mm² copper-core cable).
Three-phase circuits use three-core or four-core cables, while single-phase circuits use two-core or three-core cables.