High voltage insulators are necessary for the function of numerous power generation products, including motors and hairpin motors for electric and hybrid vehicles. These insulation solutions are also critical to keep those working around and with power generation products safe. So, how do high voltage insulators work, and what options are on the market?
What are High Voltage Insulators?
Insulators are materials that hinder the free flow of electrons. These insulators form a barrier between two energized parts of a circuit and reduce or eliminate the flow of electrons, the electric current, and heat to wires or other conducting materials. Not only are these insulating solutions used to prevent the flow of electricity and heat to areas where they are not desired, but they are also used to optimize ground wall thickness and improve voltage endurance.
What Makes a Good High Voltage Insulator?
There are a few properties that make certain materials good high-voltage insulators. Each of these properties prevents electrons and heat from transferring from one place to another.
Low Thermal Conductivity
When a material has low thermal conductivity, it is unable to conduct heat efficiently. These materials, thus, prevent heat transfer and limit the amount of free electrons in the system. Since they block heat and electrons from moving freely, they try to find other ways to transfer, all of which are significantly less efficient, thus making the system safer.
Good Dielectric Strength
Dielectric strength is the insulator’s ability to resist electrical breakdown. Since high-voltage insulators are going to be exposed to large quantities of electrical voltages, they must have a high dielectric strength to be successful.
Mechanical Strength and Durability
Many times, insulators, particularly high voltage insulators, are subjected to extreme conditions and harsh environments. These materials will need to have high mechanical strength to withstand extreme weather conditions, and they must be highly durable to have a long service life despite environmental and mechanical fatigue.
Thermal Stability
Electrical currents will generate a great deal of heat, and insulators need to be able to withstand these extreme temperatures. The best high-voltage insulation will have a high thermal stability so they do not fail or become deformed in the presence of high temperatures.
What High Voltage Insulation Options Are There?
There are many types of high-voltage insulation solutions on the market, each of which is designed to meet different needs. At Electrolock, we carry various types of high voltage insulation products.
Irradiated Polyethylene Film
Irradiated polyethylene film exhibits excellent electrical insulation, making it ideal for use as the outer sealing layer on high-voltage coils that are processed in an asphalt autoclave. At Electrolock, we carry Electrolock 525-IPB, which is a black irradiated polyethylene release film.
Mica Film
Mica exhibits low thermal conductivity and is non-flammable, making it a great option for insulation. Electrolock carries various types of high voltage insulation that include mica:
- Calmicaglas®: This insulation material consists of mica paper that is based on uncalcined muscovite or calcined muscovite. Several types of Calmicaglass® are used for the insulation of coils and bars of low and high-voltage machines, motors and generators up to the highest output and nominal voltage, electrical motors and generators, and air and indirect gas-cooled electrical machines.
- Conductofol®: This high voltage insulation solution is made of mica paper based on calcined muscovite that is impregnated with resin and a PET film. We create many types of Conductofol® that are used in the insulation of copper conductors for high and low voltage machines in various applications and environments.
Polyester
Polyester has excellent mechanical strength, wear resistance, and electrical insulating properties. Electrolock’s Contafel® is a polyester insulation option. Each of our Contafel® polyester products is uniquely tailored to various applications including protecting tapes on coils and bars for high voltage machines, VPI, and RR processes.
Electrolock Is Here to Help Innovate Your High Voltage Insulation Solutions
Since 1957, Electrolock has been engineering solutions for high voltage, battery, and thermal insulation industries. We carry many types of high voltage, battery, thermal, and wire and cable insulation solutions. And, if you can’t find a solution that meets your needs, our team will work with you to design and manufacture a solution that fits your specifications.
Contact our team today to get started.
