Material selection for AISG cables: from conductor to insulation

1, Selection of conductor materials
The conductor is the core part of the cable for transmitting current, and its material directly affects the conductivity and mechanical strength of the cable. In AISG cables, commonly used conductor materials mainly include copper and aluminum.
Copper conductor
Copper is widely used as a conductor material for AISG cables due to its excellent conductivity and good mechanical strength. Copper's conductivity is second only to silver, but silver is expensive, making it a more economical and practical choice in practical applications. Copper conductors have good corrosion resistance and can maintain stable working conditions under various harsh environmental conditions. In addition, copper conductors also have good plasticity and processability, making it easy to manufacture cables of various specifications and shapes.
Aluminum conductor
Compared to copper conductors, aluminum conductors are more affordable and have abundant resources. In certain application scenarios, aluminum conductors can serve as a substitute for copper conductors to reduce the cost of cables. However, the conductivity of aluminum conductors is slightly inferior to that of copper conductors, and their mechanical strength is lower, making them susceptible to deformation or fracture due to external environmental influences. Therefore, in situations where high conductivity and mechanical strength are required, copper conductors are still the preferred choice.
In AISG cables, the selection of conductor materials should be determined based on specific application scenarios and requirements. For applications that require high conductivity and stability, copper conductors are the best choice; For occasions with high cost requirements, aluminum conductors can be considered, but attention should be paid to their mechanical strength and corrosion resistance limitations.
2, Selection of insulation materials
The insulation layer is a critical component that protects conductors from external interference and damage. In AISG cables, the choice of insulation material directly affects the electrical performance, high temperature resistance, and wear resistance of the cable.
Polyvinyl chloride (PVC) insulation material
Polyvinyl chloride is a commonly used insulation material with excellent electrical insulation and wear resistance properties. It can maintain stable performance over a wide temperature range, with low cost and easy processing and manufacturing. However, PVC insulation materials are prone to softening or deformation in high temperature environments, leading to a decrease in the electrical performance of cables. Therefore, PVC insulation material is suitable for applications with low temperature and low requirements for high temperature resistance.
Polyethylene (PE) insulation material
Polyethylene is an excellent insulation material with excellent electrical insulation properties and high temperature resistance. It can maintain stable performance in high temperature environments and has good wear resistance. PE insulation material also has good flexibility and processing performance, making it easy to manufacture cables of various specifications and shapes. However, the cost of PE insulation material is relatively high, and it may be susceptible to chemical erosion in certain special environments.
Cross linked polyethylene (XLPE) insulation material
Cross linked polyethylene is an insulating material formed by crosslinking polyethylene molecular chains through chemical or physical methods. XLPE insulation material has excellent electrical insulation performance, high temperature resistance, and wear resistance. It can maintain stable performance in harsh environments such as high temperature, high humidity, and strong electric fields. In addition, XLPE insulation material also has good mechanical strength and anti-aging performance, which can extend the service life of the cable. However, the cost of XLPE insulation material is relatively high and the manufacturing process is relatively complex.
In AISG cables, the selection of insulation materials should be determined based on specific application scenarios and requirements. For occasions that require high electrical insulation performance and high temperature resistance, XLPE insulation material is the best choice; For occasions with high cost requirements, PVC or PE insulation materials can be considered, but attention should be paid to their limitations in high temperature resistance and wear resistance.
3, Selection of other auxiliary materials
In addition to conductors and insulation materials, AISG cables also require the use of other auxiliary materials to enhance their performance and stability. These auxiliary materials include sheath materials, shielding materials, and filling materials.
Jacket material
The sheath layer is the protective layer on the outside of the cable, which can prevent the cable from being physically damaged and corroded by the external environment. Common sheath materials include PVC, rubber, and chlorinated polyolefins. These materials have good waterproof, oil resistant, and corrosion-resistant properties, which can protect cables from external environmental damage. When selecting sheath materials, attention should be paid to their mechanical strength, wear resistance, and weather resistance to ensure that the cable can maintain a stable working state under complex and changing environmental conditions.
Shielding material
The shielding layer is one or more layers of metal mesh or metal foil inside the cable, which can prevent external electromagnetic interference and radio frequency interference from affecting the internal signals of the cable. Common shielding materials include copper foil, aluminum foil, and woven copper mesh. These materials have good conductivity and shielding effect, which can enhance the anti-interference ability of cables. When selecting shielding materials, their thickness and shielding effect should be determined based on specific application scenarios and requirements.
Filling material
Filler material is a material used to fill the gaps inside the cable, which can enhance the mechanical strength and stability of the cable. Common filling materials include polypropylene fiber, glass fiber, asbestos, etc. These materials have good mechanical strength and high temperature resistance, which can enhance the durability and reliability of cables. When selecting filling materials, attention should be paid to their mechanical strength, high temperature resistance, and chemical stability to ensure that the cable can maintain a stable working state under harsh environmental conditions.