New energy cable (For example, it is used in photovoltaic, wind power, new energy vehicles, energy storage systems and other scenarios) The requirements for temperature resistance, weather resistance, chemical resistance, mechanical strength and environmental protection of insulation materials are extremely high, and suitable materials need to be selected according to the characteristics of different application scenarios (such as temperature, voltage, environmental media). The following are the main insulation material selection and application scenarios: Polyolefin materials are the most commonly used insulation materials for new energy cables due to their excellent electrical performance, aging resistance and environmental protection, including:
Cross linked polyethylene (XLPE)
PV cable (DC below 1.5kV), wind power cable (fixed laying in engine room), low-voltage cable of energy storage system (≤ 1kV);
The advantage lies in high cost performance ratio, suitable for large-scale outdoor or indoor dry environment.
High temperature resistance (long-term working temperature 90 ℃, short-term resistance 130 ℃), high insulation resistance, high dielectric strength (≥ 20kV/mm);
Excellent mechanical strength (tensile strength ≥ 12MPa), good resistance to environmental stress cracking, strong UV resistance and weather resistance.
Performance characteristics ：
Applicable scenarios ：
Irradiation crosslinked polyolefin (XLPO, such as EVA, PE blends)
High voltage cables for new energy vehicles (600V-1kV, oil resistant and vibration resistant) Charging pile cable (Frequent bending and weather resistance);
The cables in the wind power tower barrel (which need to be resistant to low temperature and torsion) are particularly suitable for scenarios with dual requirements of environmental protection and temperature resistance.
Through electron beam irradiation crosslinking, the temperature resistance grade is improved to 125 ℃ - 150 ℃, and the oil resistance and chemical corrosion resistance are better than ordinary XLPE;
Good flexibility (elongation at break ≥ 300%), excellent low-temperature performance (- 40 ℃ still keeps elasticity), halogen-free and low smoke (in line with environmental requirements).
Performance characteristics ：
Applicable scenarios ：
Thermoplastic elastomer (TPE/EPDM)
The internal connecting cable (low voltage, small section) of the energy storage battery pack and the internal lead of the photovoltaic module are suitable for scenarios requiring high flexibility and processing efficiency.
Temperature resistance 105 ℃ - 125 ℃, good elasticity, ozone aging resistance, recyclable;
Processing convenience is better than cross-linked materials, and it is suitable for the insulation layer of cables with complex structures (such as multi-core cables).
Performance characteristics ：
Applicable scenarios ：
Fluoroplastics have excellent temperature resistance, chemical resistance and weather resistance, and are suitable for extreme environments, but the cost is high:
Perfluoroethylene propylene (FEP)
Wind power cables under high temperature environment (such as near the generator, the temperature is more than 150 ℃), and high-voltage cables in the photovoltaic combiner box (DC above 10kV);
Chemical energy storage system cable (contact with corrosive medium).
The temperature resistance grade is 150 ℃ - 200 ℃, with excellent dielectric performance (dielectric constant ≤ 2.1), oil resistance, acid and alkali resistance, and solvent corrosion resistance;
Non combustible (oxygen index>95), good radiation resistance, but medium mechanical strength (tensile strength ≥ 15MPa).
Performance characteristics ：
Applicable scenarios ：
Polytetrafluoroethylene (PTFE)
Cables in extreme high temperature environment (such as those near the photothermal power generation system and the new energy vehicle motor) and high-voltage superconducting cable insulation layer are the "ultimate choice" that cannot be replaced by other materials.
Extremely strong temperature resistance (long-term 260 ℃, short-term 300 ℃), insulation performance is almost not affected by temperature and frequency, and the weather resistance is unlimited (can be used outdoors for more than 50 years);
However, the material is hard, poor flexibility, and difficult to process (special extrusion process is required).
Performance characteristics ：
Applicable scenarios ：
Ethylene tetrafluoroethylene copolymer (ETFE)
Offshore wind power cable (seawater corrosion resistance, UV resistance), photovoltaic support integrated cable (long-term weather resistance required).
Temperature resistance 150 ℃, mechanical strength higher than FEP (tensile strength ≥ 20MPa), good flexibility, strong weldability;
Excellent weather resistance, suitable for outdoor long-term exposure scenarios.
Performance characteristics ：
Applicable scenarios ：
Silicone rubber (SR)
Performance characteristics : Temperature resistance - 60 ℃ - 200 ℃, excellent flexibility, ozone and arc aging resistance, but high cost, low mechanical strength (tensile strength ≥ 6MPa).
Applicable scenarios : High voltage harness of new energy vehicles (frequently bent, high temperature resistant in engine compartment), wind power slip ring cable (anti torsion).
Polyurethane (PU)
Performance characteristics : Excellent oil resistance and wear resistance, temperature resistance 80 ℃ - 120 ℃, good flexibility, but poor weather resistance (easy hydrolysis).
Applicable scenarios : New energy vehicle charging gun cable (plug and pull abrasion resistant, oil resistant), indoor energy storage cabinet connecting cable (short-term use).
The selection of insulation materials for new energy cables needs to be closely linked to * * "environmental adaptability" * * Core: in ordinary scenarios, cross-linked polyolefins (XLPE, XLPO) with high cost performance ratio are preferred; Irradiated XLPO or fluoroplastic (FEP) is selected for medium and high-end scenarios (such as new energy vehicles and wind power); Extreme environment (high temperature, strong corrosion) must rely on PTFE and other special fluorine materials. At the same time, environmental protection (halogen-free and low smoke is the trend) and processability (irradiation equipment is required for cross-linked materials, and special extruder is required for fluoroplastics) should be considered to balance performance and cost. Different manufacturers will focus on the equipment adaptation of certain materials according to their own technical advantages (for example, manufacturers specializing in fluoroplastic extruders are better at processing high-temperature cable insulation layer), and the selection needs to match materials and equipment according to the parameter requirements of specific scenarios.
