Cross-linked Polyolefins (XLPO) and Cross-linked Polyethylene (XLPE) are two common engineering materials used in cable jacket and insulation, piping systems, and other industrial applications. They are both cross-linked to provide excellent thermal stability, weather resistance, and mechanical properties. However, there are some differences in composition, performance, and typical applications that determine their applicability in specific application scenarios.
This article will systematically compare the definitions, structural characteristics, production methods, and pros and cons of these two types of materials to help users make reasonable material selection decisions.
Cross-linked polyolefins are a class of olefin polymers that are cross-linked by chemical or physical means, mainly polyethylene (PE) and polypropylene (PP). The cross-linking process introduces stable cross-links between molecular chains, which significantly improves their heat resistance, mechanical strength, and chemical corrosion resistance.
Due to its good flame retardant properties, low smoke and halogen-free properties, and excellent flexibility, XLPO is widely used in wire and cable insulation and jacketing, heat shrink products, automotive electronic components, and various industrial membranes.
Cross-linked polyethylene (XLPE) is a specific form of cross-linked polyolefin, and its base material is pure polyethylene. Through cross-linking, the material has significantly improved thermal stability and mechanical strength. Compared with other types of cross-linked polyolefins, XLPE exhibits higher structural rigidity and excellent waterproof and moisture-proof properties. Therefore, it is widely used in high-voltage cable insulation, water supply pipelines and heat transmission systems. It is an ideal solution for high voltage and high humidity conditions.
XLPE mainly has the following cross-linking methods:
·UV cross-linking
·Irradiation cross-linking
·Peroxide cross-linking (also commonly known as: silane cross-linking)
Compared with XLPO, XLPE usually has higher rigidity and better waterproofness. These characteristics make it the preferred material for high-voltage transmission cables, hot water pipelines and heating systems.
Angreen's Flame Retardant XLPE
To facilitate understanding of the specific differences between the two, the following analysis is made from the key performance dimensions:
XLPO: includes cross-linked polyethylene, polypropylene and their mixed systems, usually with specific additives such as flame retardants to enhance the overall performance.
XLPE: refers to pure polyethylene material that has been cross-linked and does not contain other olefin polymers, specifically cross-linked polyethylene.
| Features | XLPO | XLPE |
| Base resin | Polyethylene, Polypropylene | Polyethylene only |
| Additives | Crosslinker, flame retardant, stabilizer | Cross-linking agent, flame retardant |
| Custom blends | Yes | Limited content |
Chart 1: Material Composition
Both have higher heat resistance than their uncrosslinked state. XLPO can be formulated for optimization, especially in flame retardant systems, and its performance at high temperatures is often more stable.
| Features | XLPO | XLPE |
| Maximum operating temperature | 125℃–150℃ | 90°C–120°C |
| Heat aging resistance | High | Medium to high |
| Flame retardant options | Flame retardant | Limited flame retardancy |
Chart 2: Thermal Properties
XLPE has excellent mechanical strength and electrical insulation properties and is the mainstream material in the field of medium and high voltage cables.
In contrast, XLPO is softer and has good impact and tear resistance, making it suitable for dynamic loads or complex routing environments.
| Features | XLPO | XLPE |
| Flexibility | High | Good |
| Tensile strength | Good | High |
| Dielectric strength | Good | High |
| Elongation | High | Good |
Chart 3: Mechanical and Electrical Properties
XLPE has a lower absorption rate for moisture and is suitable for high humidity or buried environments. XLPO is more resistant to oil and chemicals and is suitable for chemical or automotive environments.
| Features | XLPO | XLPE |
| Waterproof | Good | High |
| Oil/chemical resistant | High (with additives) | Good |
| UV resistant | Good (with stabilizers) | Good |
Chart 4: Environmental Resistance
XLPO has a relatively high manufacturing cost due to its complex formula design and sophisticated processing technology; while XLPE has a mature production process, good material stability, and more advantages in overall cost control, making it suitable for large-scale standardized applications.
| Factors | XLPO | XLPE |
| Dealing with complexity | High | Good |
| Manufacturing Cost | High | General |
| Recyclability | Normal | General |
Chart 5: Processing and Cost
Angreen's Tear Resistance XLPE
Cross-linked polyolefin (XLPO) and cross-linked polyethylene (XLPE) are widely used in electrical insulation and cable applications.
XLPO:
Its commonly used in heat shrink tubing and flame retardant cable sheathing due to its excellent halogen-free flame retardancy, low smoke emission and halogen-free composition. These properties make it an ideal choice for environments such as automotive wiring harnesses, rail transit, elevator shafts, and public building cable systems. Its flexibility and oil and chemical resistance also make it very suitable for automotive and industrial cable sheathing.
XLPE:
Its high insulation strength, strong moisture resistance and good long-term reliability, even in humid or corrosive environments, can maintain stable performance, so it is widely used in power transmission and distribution cables, buried power grids and hot water pipes.
| Applications | XLPO | XLPE |
| Heat shrink tubing | Yes | No |
| High voltage cable insulation | No | Yes |
| Automotive wiring harnesses | Yes | Yes |
| Underground power cable | No | Yes |
| Flame retardant cable jacket | Yes | No |
| Photovoltaic cable jacket and insulation | Yes | Yes |
How to Choose Between XLPO vs XLPE?
The selection of appropriate materials should be based on actual working conditions:
If the project focuses on:
Flame retardant performance
Flexibility and mechanical shock resistance
Smoke and harmful gas emission control
Space-limited or vibration environment
→ XLPO is Recommended.
If the application scenario requires:
Long-term voltage resistance
Excellent moisture resistance
Installation in underground or high-humidity areas
Material cost control
→ XLPE is More Suitable.
Although XLPO and XLPE are both derived from olefin polymers and their performance is enhanced by cross-linking technology, they each have their own advantages in structure, performance and applicable scenarios. Understanding their core differences can help engineers make more targeted material choices in the fields of electrical, cable, pipeline and automation.
If further selection suggestions are required, it is recommended to conduct a comprehensive evaluation based on the specific use environment, voltage level, temperature and humidity conditions and regulatory requirements.
