Answer Posted / paul abernathy

Hello All-

While all of the answers are for the most part technically correct they do not answer the fundamental question presented. The differences in PVC versus XLPE is that PVC can be extruded, melted and re-extruded (or formed as Thermoplastic compound) while XLPE is a thermoset (or setting) which means it is not capable or regaining it's thermal melting point to be reconfigured or re-extruded. Due to these properties (melting is a result of heat) Thermoset is by it's nature prone to better results in higher temperature environments.

At the end of the day, insulation is insulation and both Thermoplastic or Thermoset have temperature ratings (in terms of wire/cable) at 90 °C . However, the thermoset properties of thermal breakdown are better in this case. Typical building wiring uses Thermoplastic (THHN/THWN-2) which is a PVC Thermoplastic product. However, the use of Thermoset insulation like XHHW (notice the "X") does have a higher property for potential temperature values even if the baseline for NEC use is 90 °C . For example, in an emergency situation the XLPE insulation threshold can reach up to 140 °C depending on the various standards employed.

Crosslinking improves the elevated-temperature properties of the base polymer. Adequate strength to 120–150 °C is maintained by reducing creep, 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.

They key is this in terms of product manufacturing, the thermoplastic insulation is always less mils than the thermoset insulation and thermoplastic tends to have (not required) a nylon outer coating to the insulation which adds some protective value which is gained in XLPE without the nylon due to an increased mils insulation value.

Hope this was helpful.

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