Molten Dripping of Crosslinked Polyethylene Cable Insulation Under Electrical Overload

Under electrical overload conditions, the molten dripping of thermoplastic wire insulation materials—particularly crosslinked polyethylene (XLPE)—poses a severe fire hazard and significantly complicates fire prevention and control. This study systematically investigated the formation mechanism, periodic characteristics, and flame interaction behavior of molten dripping in XLPE-insulated wires subjected to varying overload currents (0–80 A). Experiments were conducted using a custom-designed test platform equipped with precise current regulation and high-resolution video imaging systems. Key dripping parameters—including the initial dripping time, dripping frequency, and period—were extracted and analyzed. The results indicate that increased current intensifies Joule heating within the conductor, accelerating the softening and pyrolysis of the insulation, thus resulting in earlier and more frequent dripping. A thermodynamic prediction model was developed to reveal the nonlinear coupling relationships between the dripping frequency, period, and current, which showed strong agreement with the experimental data, especially at high current levels. Further flame morphology analysis showed that molten dripping induced pronounced vertical flame disturbances, while the lateral flame spread remained relatively unchanged. This phenomenon promotes vertical flame propagation and can trigger multiple ignition points, thereby increasing the fire complexity and hazard. The study enhances our understanding of the coupling mechanisms between electrical loading and molten dripping behavior and provides theoretical and experimental foundations for fire-safe wire design and early-stage risk assessment.