Compared to cross-linked polyethylene, polypropylene has a thermoplastic property and the advantage of recycling. However, the poor impact resistance at low temperature and the corresponding space charge problem restrict the application of polypropylene with the extruded high voltage direct current (HVDC) cable. Sufficient introduction of the β form of the polypropylene crystal can significantly improve impact resistance at low temperatures. Although it has been widely applied in insulation engineering, the effect of β-crystal on the space charge characteristics of polypropylene has rarely been researched until now. In this paper, a rare earth nucleating agent of β-crystal is employed to modify the performance of polypropylene to investigate the effects of nucleating agent content on β-crystalline, mechanical relaxation, trap, and space charge characteristics of polypropylene. The results of differential scanning calorimeter (DSC) and X-ray diffraction (XRD) tests indicate that the relative content of β-crystal in modified polypropylene increases gradually with the increasing concentration of the nucleating agent, approaching 43.5% when the nucleating agent content has been raised to 0.2 wt %, suggesting appreciable efficiency of the nucleating agent utilized in our research. Scanning electron microscopy (SEM) is utilized to characterize the morphology of β-crystal spherulites, which illustrates that the β-spherulites are in bunchy shape, and the lamellar crystals are parallel to each other without an obvious boundary between them. The results of the space charge test demonstrate that the modified polypropylene can substantially suppress space charge accumulation, which is attributed to an increment of β-crystal content by adopting a rare earth nucleating agent. It is indicated from dynamic mechanical analysis (DMA) measurements that the enhancement of β-crystalline in modified polypropylene can distinctly increase and decrease the β and α relaxation losses, respectively, which proves that the defects in β-crystal and amorphous regions are reduced and increased respectively. Thermally stimulated depolarization current tests further confirm that the number of traps caused by defects in the β-form of polypropylene crystal declines definitely, which dominantly accounts for the suppression of space charge accumulation.

Compared with traditional insulation materials, such as cross-linked polyethylene (XLPE), polypropylene (PP) is famous for its better recyclable and thermal properties, as well as its good electrical performance. However, the problem of poor impact strength has restricted the application of pure PP in high-voltage, direct current (HVDC) cables. In this paper, styrene-ethylene-butylene-styrene block copolymer (SEBS) was used as a toughening filler, and nano-SiO₂ was expected to improve the electric properties of the nano-composite. By controlling the masterbatch system, the dispersion characteristics of nano-SiO₂ in the ternary composite system were changed. When PP/SiO₂ was used as the masterbatch and then blended with SEBS, nano-SiO₂ tended to disperse in the PP phase, and the number of nano-particles in the SEBS phase was lower. When PP/SEBS was used as the masterbatch, nano-SiO₂ was distributed in both the PP phase and the SEBS phase. When SEBS/SiO₂ was used as the masterbatch, nano-SiO₂ tended to be dispersed in the SEBS phase. The different dispersion characteristics of nano-SiO₂ changed the crystallization and mechanical properties of the ternary composite system and produced different electrical performance improvement effects. The results of our experiment revealed that the space charge suppression capability was positively correlated with the direct current (DC) breakdown strength improvement effect. Compared with the DC performance of 500 kV commercial XLPE materials, the self-made PP-based ternary composite system has better space charge suppression effects and higher DC breakdown strength. When nano-SiO₂ was more dispersed in the PP phase, the space charge improvement effect was best. When the nano-SiO₂ particles were more dispersed in the SEBS phase, the expected electrical property improvement was not obtained. Scanning electron microscopy showed that the nano-SiO₂ particles in the SEBS phase were more dispersed at the interface than in the SEBS matrix, indicating that the nano-particles were poorly dispersed, which may be a reason why the electrical properties of the composite system were not significantly improved.

In order to achieve both high toughness and favorable dielectric properties of polypropylene materials, a styrene–butadiene–styrene block copolymer (SEBS) was employed as a toughening filler, in addition to a copolymerized polypropylene grafted by maleic anhydride (cPP-g-MAH) as a compatibilization modifier, to develop a novel isotactic polypropylene (iPP) composite (cPP-g-MAH/iPP/SEBS composite) with significantly improved direct-current (DC) dielectric performance and tenacity. The underlying physical and chemical mechanisms of modifying electric insulation were studied utilizing micro-structure characterization methods in combination with multiple thermal–mechanic–electric tests. The SEBS phase islands are uniformly distributed in the PP matrix with evidently improved dispersion due to cPP-g-MAH compatibilization. Compared with iPP, the elastic modulus of cPP-g-MAH/iPP/SEBS composites can be reduced by 58% with doubled thermal elongation, which is still superior to that of cross-linked polyethylene (XLPE), implying that the composites are qualified in terms of mechanical properties for use as power cables. The space charge accumulation and electric conduction are considerably suppressed in comparison with pure iPP and the iPP/SEBS composite. In the interest of charge-trapping characteristics modified by chemically grafting MAH, the deep traps introduced into polypropylene by grafting MAH were measured with a thermal stimulation current experiment to be 1.2 and 1.6 eV of energy level in trapping depth, verified through the first-principles electronic structure calculations with an all-electron numerical orbital scheme. It was concluded that the acquired high density of deep traps can effectively restrict the carrier transport and suppress the injection of space charge, resulting in a remarkable improvement of DC dielectric properties for the MAH grafted composites. The present work demonstrates that the cPP-g-MAH/iPP/SEBS composites are eligible to be applied to polypropylene-based high-voltage DC cables due to their excellent DC insulation performance, together with the appropriate mechanical properties.

The insulation layer of deep-sea optoelectronic composite cables in direct contact with high-pressure and highly corrosive seawater is required for excellent water resistance, environmental stress cracking resistance (ESCR), and the ability to withstand high DC voltage. Although high-density polyethylene (HDPE) displays remarkable water resistance, it lacks sufficient resistance to environmental stress cracking (ESCR). This article is based on a blend modification approach to mixing HDPE with different vinyl copolymer materials (cPE-A and cPE-B). The processing performance and mechanical properties of the materials are evaluated through rheological and mechanical testing. The materials’ durability in working environments is assessed through ESCR tests and water resistance experiments. Ultimately, the direct current electrical performance of the materials is evaluated through tests measuring space charge distribution, direct current resistivity, and direct current breakdown strength. The results indicate that, in the polyethylene blend system, the rheological properties and ESCR characteristics of HDPE/cPE-A composite materials did not show significant improvement. Further incorporation of high melt index linear low-density polyethylene (LLDPE) material not only meets the requirements of extrusion processing but also exhibits a notable enhancement in ESCR performance. Meanwhile, copolymerized polyethylene cPE-B, with a more complex structure, proves effective in toughening HDPE materials. The material’s hardness significantly decreases, and when incorporating cPE-B at a level exceeding 20 phr, the composite materials achieve excellent ESCR performance. In a simulated seawater environment at 50 MPa, the water permeability of all co-modified composite materials remained below 0.16% after 120 h. The spatial charge distribution and direct current resistivity characteristics of the HDPE, cPE-A, and LLDPE composite systems surpassed those of the HDPE/cPE-B materials. However, the HDPE/cPE-B composite system exhibited superior dielectric strength. The application of composite materials in deep-sea electro–optical composite cables is highly promising.