Recyclable thermoplastic insulation with improved breakdown strength

1. A process comprising:

heating a polymeric composition consisting of (i) a low density polyethylene having a melting temperature of at least 105° C. to 125° C. (LDPE) (ii) a minority amount of a high density polyethylene having a melting temperature of at least 130° C. to 134° C. (HDPE), and (iii) optional antioxidant, to at least the melting temperature of the HDPE;

control-cooling the heated polymeric composition at a cooling rate from 0.1° C./min to 10° C./min; and

forming a polymeric composition having a space-filling array of HDPE lamellae, which are separated by the LDPE, the polymeric composition having an AC breakdown strength greater than 170 kV/mm as measured on 85 micrometer thin films in accordance with ASTM D 149.

2. The process of claim 1 comprising:

melt blending from about 5 wt % to about 35 wt % HDPE and from about 95 wt % to about 65 wt % of the LDPE, and

forming the polymeric composition.

3. The process of claim 1 comprising heating the polymeric composition to at least 130° C.; and control-cooling from 130° C. to 90° C.

4. The process of claim 1 comprising heating the polymeric composition to at least 130° C.; and

control-cooling the heated polymeric composition at a rate from 0.1° C./min to 10° C./min from 130° C. to 90° C.

5. The process of claim 1 comprising heating the polymeric composition to at least 130° C.;

control-cooling from 130° C. to 90° C.; and

quenching when the temperature of the heated polymeric composition is less than 105° C.