Insulating Materials

Classification and Its

Applications
Contents

• Introduction to Insulating Materials

• Characteristics of a Good Insulating Material
• Classification of Insulating Materials
• Air Spaces in Insulation
• Effect of Moisture on Insulation
• Protection of Insulation against Moisture
• Applications of Insulating Materials
1. Introduction to Insulating
Materials
• Electrical insulating materials are defined as materials which offer a
very large resistance to flow of current, and for that reason they are
used to keep the current in its proper path along the conductor.

• A large number of substances and materials may be classified as

insulators, many of which have to be employed in practice, as no single
substance or material can satisfy all the requirements involved in the
numerous and varied applications of insulators in electrical engineering.
Such requirements involve consideration of physical properties,
reliability, cost, availability, adaptability to machining operations etc.
• Thus in some applications the insulating material in addition to its
function as an insulator may have to act as a rigid mechanical support
to the conductor and may be installed out of doors, in which case the
insulating qualities must be retained under all atmospheric
conditions, in other cases extreme flexibility is required.

• Again, in electric heaters the insulating materials must maintain their

insulating qualities over a wide range of temperatures extending in
some cases to 1100°C, and for radio purposes the insulating qualities
must be maintained upto very high frequencies.
• In electrical machines and transformers the insulating materials
applied to the conductors are required to be flexible, to have high
specific electric strength (to reduce thickness to minimum) and ability
to withstand unlimited cycles of heating and cooling.
2. Characteristics of a Good
Insulating Material
A good insulating material should possess the following characteristics
1. Large insulating resistance.
2. High dialectic strength.
3. Uniform viscosity—it gives uniform electrical and thermal properties.
4. Should be uniform throughout—it keeps the electric losses as low as
possible and electric stresses uniform under high voltage difference.
5. Least thermal expansion.
6. When exposed to arcing should be non-ignitable.
7. Should be resistance to oils or liquids, gas fumes, acids and alkalies.
8. Should have no deteriorating effect on the material, in contact with it.
9. Low dissipation factor (loss tangent).
10. High mechanical strength.
11. High thermal conductivity.
12. Low permittivity.
13. High thermal strength.
14. Free from gaseous insulation to avoid discharges (for solids and gases).
15. Should be homogeneous to avoid local stress concentration.
16. Should be resistant to thermal and chemical deterioration
[Link] of Insulating
Materials
• The insulating materials can be classified in the following two ways:

1. Classification according to substances and materials.

2. Classification according to temperature.

1. Classification According to
Substances and Materials
(i) Solids (Inorganic and Organic):
Mica, wood, slate, glass, porcelain, rubber, cotton, silk, rayon, terylene,
paper and cellulose materials etc.
(ii) Liquids (Oils and Varnishes):
Linseed oil, refined hydrocarbon mineral oils, spirit and synthetic
varnishes etc.
(iii) Gases:
Dry air, carbon dioxide, argon, nitrogen etc.
2. Classification According to Temperature
4. Air Spaces in Insulation

• When an insulation is designed every attempt is made to avoid the

existence of air spaces in it. Though, it is difficult to avoid air spaces in
materials such as fabricated and impregnated insulation yet these
may be prevented by vacuum impregnation or by gas or oil filling
under pressure.
The air spaces exercise harmful effects in
the following way
When a solid insulation containing air spaces is subjected to voltage,
ionization occurs (the phenomenon being known as corona).
Consequences of ionisation include-
(i) A great power loss in the insulation;
(ii) Thermal instability;
(iii) Lowering of the breakdown voltage of the insulation;
(iv) There is carbonisation, decomposition and mechanical damage to the
insulating material.
Thus when there are air spaces in the insulation, it should not be
overstressed and the material should have corona resistance properties
 5. Effect of Moisture on
Insulation
• When an insulating material is placed in a humid atmosphere it absorbs a
certain amount of moisture. The water vapours, at first, are absorbed on
the surface, then they diffuse tending to reduce moisture concentration
gradient and finally they are desorbed into lower vapour concentration
region.

• In an insulating material moisture diffusion, as a rule, takes place when the

electrical equipment is inoperative. When the current is carried by the
electrical equipment, the moisture diffuses from the insulating material
(i.e., material dries up)
All solid dielectrics, on the basis of absorption of moisture
in highly humid atmosphere, can be classified as under:

1. Hygroscopic and wettable materials.

2. Non-hygroscopic and wettable materials.

3. Non-hygroscopic and nonwettable materials.

• The air having high humidity is a source of troubles in electrical insulation and can even cause
failure of electrical equipment
The effect of moisture on insulating
materials brings about the following changes

1. Changes in electrical properties.

2. Chemical changes.
3. Physical and mechanical changes.
1. Changes in Electrical
Properties
(i) The moisture absorbed by an insulating material causes- (a) a decrease in the
volume resistivity, and especially surface resistivity (b) an increase in the dissipation
factor and a certain increase in dielectric constant (c) decrease in dielectric strength
due to a change in field distribution within the insulating material.

(ii) Conducting bridges may appear across the surface of the insulating material under
high humidity and electric tension current.

In some cases the thin films formed of the moisture on the insulating material dries
up when the equipment is working. Such places get a carbonized spot and such spots
may join together with time and build up a conducting bridge, thus a short circuit may
result.
2. Chemical Changes
(i) High humidity often cause hydrolysis.

(ii) High humidity favours the growth of fungi in some insulating

materials, which in turn degrade organic insulating materials.
3. Physical and Mechanical
Changes
(i) Some materials like plastics, polymers and materials filled with
cellulose filters swell in the presence of high humidity.

(ii) Mechanical strength of the insulating material is reduced in the

presence of moisture
6. Protection of Insulation
against Moisture
The insulation can be protected against moisture by following methods:

(i) Impregnation of Winding:

• The windings of all low voltage equipments are impregnated with baking
varnishes (sometimes compounds are also used). Impregnating varnishes and
compounds raise the moisture resistance of windings.

• Impregnation treatment solidifies the windings, increases their thermal

conductivity, improves their electrical and mechanical strength and heat
resistance.
(ii) Making Insulation Hydrophobic (Waterproof):

• The insulating materials assemblies sometimes are rendered hydrophobic to

protect them against moisture. This type of treatment is specifically effective for
polymers containing hydroxyls and for cellulose base insulating materials.

• In comparison to old widely used techniques employing asphalts, bitumens,

waxes, water-proofing by means of some hydrophobic silicon compositions free
of hydroxyls and carboxyls is finding ever increasing favour. Paper, cotton fabric
are rendered hydrophobic by dipping them in the solution of methyl
butoxidiamine silane in carbon tetra-chloride or methyl triethoxisilane in absolute
alcohol.
(iii) Hermetic Sealing
• Hermetic sealing (sealing by means of compounds) is widely used to
protect insulation against moisture and help in maintaining adequate
insulation properties of parts and protect them against mechanical
damage. This treatment is normally affected by coating, impregnation
and potting in compounds.
• The sealing methods in use are- Dipping, Moulding, Injection,
Encapsulation etc. The compounds most widely used in sealing the
insulation of low voltage equipment are polyester-styrene, butyl
methacrylate, styrene, polyurethane, silicon base compounds.
• The insulating material or part to be sealed must be thoroughly dried
out. The wax, asphalt or bitumens were used in old sealing methods.
 Applications of Insulating
Materials

1. Solid Insulators:
The various materials which can be used as solid insulators are given
below:
 i. Asbestos:
(a) Chemically it is a hydrated magnesium silicate. It is very useful inorganic material.
Chrysotile 3MgO, 2SiO2, 2H2O belongs to the group of fibers in nature.
(b) The fibrous structure of asbestos combined with its non-inflammability, makes it
particularly suited for thermal as well as electrical insulation.
(c) When properly impregnated and formed into suitable shapes, it is useful for many
structural purposes.
(d) It has a relatively low value of dielectric strength and provides good insulation at
low voltages but its property of resistance against heat makes it very useful in high
temperature windings such as those in railway, crane, mill or compressor motors
where wide temperature changes may be encountered. It is applied in the form of
tape, sheet or pulp. One commonly finds asbestos in welding machines, electric
ovens, electric bottles and other table appliances
ii. Bakelite:
(a) It is a synthetic resin obtained by condensation of formaldehyde
with phenol or cresol.

(b) It is heat proof, acid proof and mechanically strong.

(c) It is commonly used for manufacture of all kinds of small electrical

fittings— lamp-holders, switches, plugs etc.
iii. Cotton or Silk:

(a) Cotton is hygroscopic and has low electric strength, so it must be impregnated
with varnish or wax after winding.
(b) Cotton covered wire is extensively used for winding of small magnet coils,
armature winding of small and medium sized machines, chokes and small
transformer coils etc.
(c) Silk is more expensive than cotton but takes up less space and is therefore used
for windings in fractional horse power machines.
(d) Silk is less hygroscopic and has a higher dielectric strength than cotton, but like
cotton it requires impregnation.
(e) The operating temperature of cotton and silk is 100°C and the material carbonise
above this temperature.
iv. Mica:
(a) It is a mineral composed of silicate of aluminum with silicates of soda
potash and magnesia. It occurs in the form of crystals which can easily be
split into lamina.
(b) It is affected by oils. (c) Its dielectric strength varies from 40 to 150
kV/mm.
(d) It is least affected by heat but dehydrates at high temperature.
(e) It has high dielectric strength and low power loss. (f) It is rigid, tough and
strong.
(g) Its electrical properties are deteriorated with the presence of quartz and
feldspar.
(h) Thick mica tape is largely used for taping armature and field coils of
traction motors (in case where glass tape is not employed) and for taping the
starter coils of H.V. alternators.
v. Micanite:

(a) It is formed from mica fragments bonded by shellac varnish into

large sheets.
(b) Its dielectric strength is 30 kV/mm
(c) It is mechanically weak at high temperatures.
(d) It is used for slot lining of H.V. machines.
It is also employed for making bushes (Bush is an insulator which
enables a live conductor to pass through an earthed wall or tank)
vi. Paper:
(a) It is prepared from wood pulp and manila fibers beaten and rolled into sheets.

(b) Its dielectric strength is 4 to 10 kV/mm.

(c) It is hygroscopic and absorbent and so is particularly suitable for impregnation.

(d) Electrical properties are adequately good.

(e) It is rarely used in un-impregnated condition but can be used successfully under oil

High density papers are preferred in DC and energy storage capacitors and other DC insulation.
vii. Waxes:
• Because of their high electrical resistance and exceptional water
repellence, waxes are used as impregnating compounds in condensers
and in the radio coils used in the tropics. The common variety used is
paraffin wax.

• Insulating wax is used as an impregnating material for paper and cloth

insulation, as a dipping medium, and as a directly applied coating on
conductors
viii. Rubber:
The materials used in cable insulation are –
(i) pure rubber,
(ii) impregnated paper, and
(iii) vulcanised bitumen.

Raw rubber cannot be used as an insulating material directly because it is

brittle and hard when cold but soft and stiff when hot. In addition, it perishes
under the action of oil and air. Sulphur addition makes the product harder. If
the sulphur is added to an extent of 30%, vulcanite or ebonite is obtained
which is hard material with excellent insulating properties. The operating
temperature of rubber is 50°C
ix. Ceramics:

• Ceramic materials contain phases that are compounds of metallic and

non- metallic elements. Ceramics are mechanically hard possess good
electrical properties. The ceramics used as dielectric may be broadly
described as clay containing porcelains, alumina ceramics, talc
containing steatites and the titanates (mostly barium titanate which
have high dielectric constant)
x. Resins or Polymers:
(a) Resins are organic substances with very high molecular weight. They
are available in nature as well as artificially made. Synthetic resins are
synthetic polymers known as plastics and form an important group of
insulating materials.

(b) They are bad conductors of electricity and unsuitable for high
temperature service.

(c) They have high dielectric strength

xi. Glass:
(a) Ordinary glass is a good insulator but it is too brittle to be used for anything; scientific instrument
parts, containers etc.

(b) Toughened glass is employed for insulation in extra H.V. lines having voltage above 100 kV. It is
produced by processing ordinary glass to desired shape at about 100°C and then cooling quickly in
compressed air current.

(c) The electric strength of toughened glass under lighting conditions is 3-4 times, higher than that of
porcelain.

(d) Glass is used in the production of glass fiber formatting tapes similar to cotton or silk tapes.

(e) It is widely used as an insulating material to form the envelop and for internal supports in electric
light bulbs, electronic valves, X-ray tubes etc.
2. Liquid Insulators:
Liquid insulators are used in transformers, regulators and oil circuit
breakers where they help to dissipate the heat generated by
convection. They are also used for impregnation of solid insulators like
paper (in cables).

A low viscosity oil is required for easy flow. Dielectric strength which is
important in all cases is affected greatly by the presence of moisture
and other impurities such as dissolved gases. They are mineral oils
consisting of complex series of hydrocarbons obtained from refining of
crude oils.
As the principal use was in transformer in the early stage of
development, they are given the name transformer oil. The oil before
being used is made free from moisture and filtered to remove sludge
etc.

Synthetic liquid dielectrics, e.g., Pyranol, Inerteen etc. have replaced

mineral oils because they, in addition to insulating properties, possess
the property of being non-inflammable and do not emulsify water.
3. Gaseous Insulators:
• Gaseous insulators are used both as an insulants and heat transfer
medium. The major problems associated with them are the
abnormalities in dielectric behaviours at high pressure, temperature
instabilities and fire hazards.

• Although, all known gases are dielectric gases when pure, but from
the engineering point of view, taking into consideration the dielectric
strength, dielectric loss, chemical stability and corrosion etc. they may
be classified as:
i. Simple Gases:

This group includes air, nitrogen, neon, hydrogen, helium, argon etc.
ii. Oxide Gases:

• Carbon dioxide, sulphur dioxide etc.

iii. Electronegative Gases:

Sulphur hexafluoride (SF6), CH2Cl2 etc.

iv. Hydrocarbon Gases:

Methane, ethane, propane, Freon etc.

 Conclusions

• For the insulation design in the equipment, the solid insulators play
the most critical role. In order to improve the insulation performance
of the solid insulators, there is a need to control the electric field
distribution around the solid insulators.
Thank You