High Performance and Recyclable Polypropylene/Styrene-Ethylene-Butylene-Styrene Blends for Next Generation Cable Insulation with Enhanced Breakdown Strength Through Controlling Crystallinity.

Reducing the environmental impact is a key reason for developing recyclable insulation materials for high-voltage industries. In this study, polypropylene (PP) blends were prepared via melt mixing with styrene-ethylene-butylene-styrene (SEBS), a thermoplastic elastomer, to improve breakdown strengths at various cooling speeds. A systematic investigation was conducted to evaluate the influence of crystal size, degree of crystallinity, and nucleation growth rate on the breakdown strength. Crystallization behavior was analyzed using isothermal and non-isothermal methods based on the Avrami model. Increasing SEBS content reduced crystallinity, with the lowest nucleation growth rate observed at 35% SEBS. Breakdown strength correlated with crystallization behavior and was further validated by Weibull distribution method. Notably, PP/SEBS blends containing 35% SEBS exhibited the highest breakdown strength of 66.4 kV/mm at a cooling speed of 10 °C/mm. This improvement reflected a reduction in the degree of crystallinity from 36.0% to 22.9% and the lowest growth rate constant (k) at 35% SEBS. Furthermore, the predicted lifetime of PP/SEBS blend containing 35% SEBS, calculated using the oxidation induction time and the Arrhenius equation, was 42 years. These findings demonstrate that SEBS content and cooling rate effectively modulate crystallization and breakdown strength, enabling recyclable PP/SEBS with XLPE-comparable performance for sustainable high-voltage insulation.