Thermoplastic cable insulation comprising a blend of isotactic polypropylene and a propylene-ethylene copolymer

There is much interest in the development of replacement materials for crosslinked polyethylene (XLPE) that are both recyclable (i.e. thermoplastic) and capable of high temperature operation. Thermally, polypropylene is the ideal choice, although its stiffness and low electrical breakdown strength make for a challenging materials design problem. We report here on the compositional optimization of a propylene homopolymer/propylene-ethylene copolymer blend in terms of its dynamic mechanical properties and thin film electrical breakdown strength. The extrusion of a trial minicable using the optimized blend is also discussed, which is shown to exhibit a significantly improved electrical performance, as gauged by its DC breakdown strength, than an XLPE-insulated reference.