Cross-Linked Polyethylene (XLPE) : Properties

Cross-Linked Polyethylene(XLPE)
Cross-linked polyethylene, commonly abbreviated PEX or XLPE, is a form of polyethylene with cross-links. It is
formed into tubing, and is used predominantly in hydronic radiant heating systems, domestic water piping and
because of the enhanced heat resistance (in terms of resistance to melt flow), cross-linked or vulcanized
polyethylene finds application in the cable industry both as a dielectric and a sheathing material for high tension
(high voltage) electrical cables. It is also used for natural gas and offshore oil applications, chemical transportation,
and transportation of sewage and slurries. Recently, it has become a viable alternative to polyvinyl chloride (PVC),
chlorinated polyvinyl chloride (CPVC) or copper pipe for use as residential water pipes. PEX tubing ranges in size
from imperial sizes of 1/4-inch to 4-inch, but 1/2-inch, 3/4-inch, and 1-inch are by far the most widely used. In metric
PEX is normally available in 16 mm, 20 mm, 25 mm, 32 mm, 40 mm, 50 mm and 63 mm sizes.
Properties
Almost all PEX is made from high density polyethylene (HDPE). PEX contains cross-linked bonds in the polymer
structure, changing the thermoplastic to a thermoset. Cross-linking is accomplished during or after the extrusion of
the tubing. The required degree of cross-linking, according to ASTM Standard F 876-93, is between 65 and 89% . A
higher degree of cross-linking could result in brittleness and stress cracking of the material.
The high-temperature properties of the polymer are improved. Adequate strength to 120-150°C is maintained by
reducing the tendency to flow. Chemical resistance is enhanced by resisting dissolution. Low temperature
properties are improved. Impact and tensile strength, scratch resistance, and resistance to brittle fracture are
enhanced.
XLPE has excellent dielectric properties, making it useful for medium voltage - 10 to 50 kV AC - and high voltage
cables - up to 380 kV AC-voltage, and several hundred kV DC.
Numerous modifications in the basic polymer structure can be made to maximize productivity during the
manufacturing process. For medium voltage applications, reactivity can be boosted significantly. This results in
higher line speeds in cases where limitations in either the curing or cooling processes within the continuous
vulcanization (CV) tubes used to cross-link the insulation. PEX insulations can be modified to limit the amount of by-
product gases generated during the cross-linking process. This is particularly useful for high voltage cable and
extra-high voltage cable applications, where degassing requirements can significantly lengthen cable manufacturing
time.
Cross-linking of a crystalline thermoplastic polymer has, in general, two distinct effects. Firstly it interferes with
molecular packing, reducing the level of crystallisation, and consequently the polymer has a lower modulus,
hardness and yield strength than the corresponding non-cross-linked material. More importantly, because the
network structure still exists above the crystalline melting point the material retains a measure of strength, typical of
a rubber material.
Three main approaches are used for cross-linking polyethylene:

(1) Peroxide cross-linking XLPE- called PEX-A
(2) Vinyl silane cross-linking XLPE- called PEX-B
(3) Radiation cross-linking XLPE- called PEX-C
PEX-A (PE-Xa, PEXa)
PEX-A is produced by the peroxide (Engel) method. This method performs "hot" cross-linking, above the crystal
melting point. However, the process takes longer and tends to be more expensive than the other two methods as
the polymer has to be kept at high temperature and pressure for long periods during the extrusion process. The
cross-linked bonds are between carbon atoms. PEX-A have the same properties as PEX-B after installation.
Equipment requirements for peroxide curing are somewhat simpler but the method requires close control. At
elevated temperatures the peroxide molecules break up, producing free radicals. These abstract hydrogen from the
polymer chain to produce a polymer free radical. In the case of polyethylene the most likely reaction is that two
radicals will combine and thus cross-link two chains but other reactions may lead to chain scission. It is important
that the peroxide be sufficiently stable thermally to withstand compounding and shaping operations without
degradation in order to avoid premature cross-linking. Dicumyl peroxide is frequently used for low-density
polyethylene but more stable peroxides are necessary for higher density materials. For cable covering, high
production rates require high curing temperatures in the absence of oxygen and this normally involves the use of
high-pressure steam in a long curing tube set into the extrusion line. Large amounts of carbon black may be
incorporated into polyethylene that is to be cross-linked. The carbon black is believed to take part in the cross-
linking process and the compounded product has superior mechanical properties in many respects to the unfilled
material. It is also to be noted that copolymers of ethylene with small amounts of vinyl acetate are often preferred for
peroxide cross-linking.
PEX-B (PE-Xb, PEXb)
The silane method, also called the "moisture cure" method, results in PEX-B. In this method, cross-linking is
performed in a secondary post-extrusion process, producing cross-links between a cross-linking agent. The process
is accelerated with heat and moisture. The cross-linked bonds are formed through silanol condensation between
two grafted vinyltrimethoxysilane (VTMS) units, connecting the polyethylene chains with C-C-Si-O-Si-C-C bridges.
After installation, PEX-B have the same properties as PEX-A. The real advantage is the fact that PEX-B is cheaper.
The process for cross-linking is the Sioplas process developed by Dow. The first stage of this involves the grafting
of an easily hydrolysable trialkoxyvinylsilane onto the polyethylene chain, the site activation having been achieved
with the aid of a small amount of peroxide. The compound is then extruded onto the wire, which is collected on a
drum. The drum is then exposed to hot water, or, more commonly, low-pressure steam. The water hydrolyses the
alkoxy groups, which then condense to form a siloxane cross-link. The cross-linking stage is facilitated by the use of
a cross-linking catalyst, which is typically an organo-tin compound. A number of variations of this process exist and
in one of these compounding, grafting and extrusion onto wire are carried out in the same extruder.
PEX-C (PE-Xc, PEXc)
PEX-C is produced through electron beam processing, in a "cold" cross-linking process (below the crystal melting
point). It provides less uniform, lower-degree cross-linking than the Engel method, especially at tube diameters over
one inch (2.5 cm). When the process is not controlled properly, the outer layer of the tube may become brittle.
However, it is the cleanest, most environmentally friendly method of the three, since it does not involve other
chemicals and uses only high-energy electrons to split the carbon-hydrogen bonds and facilitate cross-linking.
Radiation cross-linking requires expensive equipment and extensive protective measures. The technique is being
used commercially and is most suitable with thin sections.

Cross-Linked Polyethylene (XLPE) : Properties

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Cross-Linked Polyethylene (XLPE) : Properties

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Cross-Linked Polyethylene(XLPE)

Three main approaches are used for cross-linking polyethylene:

PEX-A (PE-Xa, PEXa)

PEX-B (PE-Xb, PEXb)

PEX-C (PE-Xc, PEXc)

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