ENSURING EXCELLENCE IN SOLAR CABLE MANUFACTURING: KEY MATERIAL QUALITIES, EXTRUSION CONDITIONS, AND STANDARDS

1. Required Properties of Insulation and Sheath Materials

Insulation and sheath materials are critical components that directly impact the performance and lifespan of solar cables. The key properties these materials must possess include:

1. Thermal Resistance:

   • The cable must endure continuous high temperatures (e.g., 90°C–120°C). So, the hot set values as an indication of crosslinking must be enough levels.

   • It should remain flexible and not become brittle in cold weather conditions.

2. UV and Ozone Resistance:

   • Solar cables are often exposed to prolonged sunlight outdoors. Materials must be UV-stabilized to prevent premature aging.

   • Resistance to ozone and other atmospheric effects is essential.

3. Electrical Insulation:

   • High insulation resistance and low dielectric losses are required.

   • The material must withstand high breakdown voltages to reduce the risk of electrical faults.

4. Mechanical Strength:

   • Flexibility and tensile strength are necessary to withstand physical stresses during and after installation.

5. Chemical Resistance:

   • The cable must resist oils, chemicals, acids, and alkalines it may encounter.

   • Water resistance (low water absorption) is also crucial.

6. Fire Resistance:

   • The material should be flame-retardant (fire-resistant).

   • Halogen-free materials with low smoke and non-toxic emissions are preferable (XL-LSZH).

2. Key Considerations During Cable Extrusion

1. Material Selection:

   • The polymers used must meet quality standards. XLPE (cross-linked polyethylene), XLPO (cross-linked polyolefins) or EPR (ethylene-propylene rubber) are commonly preferred.

   • Cross-linked HFFR

2. Optimization of Extrusion Parameters:

   • Extrusion temperature, speed, and pressure must be precisely calibrated. Improper settings can negatively impact material uniformity and mechanical strength.

3. Layer Thickness and Concentric Structure:

   • The thickness of insulation and sheath materials must comply with international standards.

   • A concentric structure is crucial for mechanical strength and electrical performance.

4. Cooling and Solidification:

   • Proper cooling after extrusion minimizes the risk of cracks or deformation in the cable.

5. Online Quality Control:

   • Real-time monitoring of thickness, surface smoothness, and concentricity is essential during extrusion.

3. Quality Standards for Cables

Key international standards for solar cables:

• IEC 62930: Specifications for photovoltaic system cables.

• EN 50618: European standard for solar cables, covering mechanical, electrical, and environmental resistance.

• UL 4703: North American standard for photovoltaic cables.

• RoHS and REACH Compliance: Ensures the absence of environmentally harmful substances.

Quality control tests include:

• UV resistance testing.

• High-temperature and cold flexibility tests.

• Electrical breakdown tests and insulation resistance measurements.

• Flame retardancy tests.

4. What It Takes to Produce High-Quality Cables

1. Use of High-Quality Raw Materials:

   • Certified and standards-compliant raw materials should be used.

2. Investment in R&D:

   • Continuous investment in material development and innovative manufacturing technologies is necessary.

3. Advanced Production Technologies:

   • Multi-layer cable production techniques like co-extrusion can be employed.

   • Automation and digital monitoring technologies should minimize production errors.

4. Experienced Team and Continuous Training:

   • The production team should be well-versed in material science and extrusion technologies.

5. Sustainability:

   • Recyclable and environmentally friendly materials should be prioritized for sustainable manufacturing.

Visual Description

A close-up view of solar cables in a solar farm setting, showcasing their high-quality insulation and sheath materials with smooth and durable textures. Rows of solar panels extend toward the horizon under a bright blue sky, emphasizing innovation and durability in solar cable manufacturing.

Solar Cables

Figure-1 Solar cable and solar cable system