INTRODUCTION TO INSULATING MATERIALS

There are two main classes of Insulating Materials;

 Natural Insulating Materials

 Artificial Insulating Materials

Natural Insulating Materials:

These are those insulators which are present in nature as it is and we are using them
intentionally or unintentionally. Some examples are;
 Wood
 Cotton
 Oil
 Sand
 Air
 Ice

Artificial Insulating Materials:

These are those isolators manufactured by man using composition of natural resources.
Artificial insulators are again divided into 2 main types;
 Inorganic insulators
 Organic insulators

Inorganic Insulators:
Inorganic includes Glass and Ceramic material insulators;

 Glass:
The basic source of glass is Sand. Glass insulators are
nowadays not used because glass is Fragile. But ceramic
is physically not breaking up easily.

 Ceramic:
Ceramic materials are inorganic, non-metallic materials
made from compounds of a metal and a non metal.
Ceramic materials may be crystalline or partly crystalline.
They are formed by the action of heat and subsequent
cooling. [1]

Composition:
Ceramics are composed of following ingredients.

1. Feldspar: (35%)
The feldspars are a family of silicate minerals which occur in igneous rocks.[2]
2. China Clay: (28%)
China clay, also called kaolin is a soft white clay that is an essential ingredient in the
manufacture of china and porcelain. kaolin is a white, soft powder consisting principally
of the mineral kaolinite.[3]
 3. Talc: (2%)
It is composed of Basic magnesium silicate. Talc is an important industrial mineral. Its
resistance to heat, electricity and acids make it an ideal surface for lab counter tops and
electrical switchboards.[4]
4. Ball Clay: (10%)
The name 'ball clay' derives from the former method of winning the clay by cutting it
from the floor of an open pit in cubes. They are essential components of most types of
pottery.[5]
5. Fluit: (25%)
It is also an important ingredient of Ceramic material and is 25% in composition.

Ceramic Disc:
Different shapes of ceramic discs are used depending upon
applied voltage level. Grooves are made to stop air flashovers in
HVE.

Organic Insulators:
The use of polymeric materials has become very popular since last
thirty years in many applications. Synthetic organic
resins/polymers and hardeners are used as a thermoset or thermoplastic electrical or electronic
insulation.

Types of organic insulators:

The materials in this category can be broadly divided into two categories i.e. thermoset and
thermoplastics.
1. Thermoplastics
2. Thermosets
3.
Thermoplastic
Thermoplastic is a plastic that softens upon heating and hardens when cooled. Thermoplastics
are made up of linear molecular chains and can be shaped by flow into articles by molding or
extrusion without need of any chemical processing before molding. The most useful physical
property of a thermoplastic is its glass transition temperature at which it begins to soften.

Types And Applications:

1. Chlorinated Polyethylene (CPE):
CPE is one of the few polymers available in both thermoplastic and thermoset (cross-
linked) versions. As a rule, thermoset formulations have better high-temperature properties
than thermoplastics but are also higher in cost. Thermoplastic CPE is more common than
thermoset CPE.
2. Polyvinyl Chloride (PVC):
PVC does not usually exhibit extremely high and low temperature properties in one
formulation. Certain formulations may have a –55°C to 105°C rating, while other common
vinyls may have a 20°C to 60°C rating. The many varieties of PVC also differ in and
electrical properties. When properly formulated, thermoplastic jackets of PVC provide cables
with the ability to resist oils, acids, alkalis, sunlight, heat, weathering and abrasion.
 This range of properties makes PVC a suitable outer covering for such cable types as
underground feeders (Type UF), control, aerial, street lighting and cables for direct burial.
PVC is frequently used as an impervious jacket over and/or under metal armor where the
installation requires PVC’s protective characteristics. Flamarrest is a plenum grade, PVC-
based jacketing material with low smoke and low flame spread properties.
3. Fluoropolymers:
Fluoropolymers, are extrudable thermoplastics used in a variety of low-voltage
insulating situations. Fluoropolymers contain fluorine in their molecular composition, which
contributes to their excellent thermal, chemical, mechanical and electrical characteristics.
The most commonly used fluoropolymers are Teflon (PTFE, FEP and PFA), Tefzel (ETFE),
Halar (ECTFE) and Kynar or Solef (PVDF).
Teflon has excellent electrical properties, temperature range and chemical resistance.
It is not suitable where subjected to nuclear radiation and does not have good high-voltage
characteristics. PTFE must be extruded over a silver- or nickel-coated wire. The nickel- and
silver-coated designs are rated 260°C and 200°C maximum, respectively. The cost of Teflon
is approximately 8 to 10 times more per pound than PVC compounds.
Teflon PTFE is the original Teflon resin invented by DuPont in 1938. It is an
opaque, white material, although some forms are translucent in thin sections. It does not melt
in the usual sense. To coat wire for insulating purposes, Teflon PTFE is extruded around the
conductor as a paste, then sintered. Conductors can also be wrapped with tape of Teflon
PTFE. Maximum continuous service temperature of Teflon PTFE is 260°C (500°F). Specific
advantages of wire insulated with Teflon PTFE include:
 Non-flammability
 Extremely high insulation resistance
 Very low dielectric constant
 Small size compared to elastomer insulated wires
 Excellent lubricity for easier installation
 Chemical inertness.
Teflon FEP was also invented by DuPont and became commercially available in
1960. It has a glossy surface and is transparent in thin sections. Teflon FEP is a true
thermoplastic. Wire insulated with Teflon FEP can be melt extruded by conventional
methods. Maximum continuous service temperature is 400°F (205°C). Teflon FEP is an
excellent nonflammable jacketing material for multiconductor cables. Specific advantages of
wire insulated with Teflon FEP include:
 High current carrying ability (ampacity)
 Easy color coding
 Smallest diameter of any high-temperature wire
 Nonflammability
 Very low moisture absorption.
Teflon PFA is a perfluoroalkoxy copolymer resin supplied by DuPont. Wire
insulated with PFA is rated up to 250°C (482°F) and has excellent high-temperature creep
resistance, low-temperature toughness and flame resistance.
Tefzel (ETFE) is commonly used in computer backplane wiring and has the highest
abrasion and cut-through resistance of any fluoropolymer. Tefzel is a thermoplastic material
having excellent electrical properties, heat resistance, chemical resistance, toughness,
radiation resistance and flame resistance. Tefzel’s temperature rating is –65°C to 150°C.
Kynar (PVDF) is one of the least expensive fluoropolymers and is frequently used as a jacketing
material on plenum cables. Because of its high dielectric constant, however, it tends to be a poor
insulator. PVDF has a temperature maximum of 135°C (UL).
4. Polyolefins (PO):
Polyolefin is the name given to a family of polymers. The most common polyolefins
used in wire and cable include polyethylene (PE), polypropylene (PP) and ethylene vinyl
acetate (EVA).
a) Polyethylene (PE):
Polyethylene has excellent electrical properties. It has a low dielectric constant, a
stable dielectric constant over a wide frequency range, and very high insulation resistance.
However, polyethylene is stiff and very hard, depending on molecular weight and density.
Low density PE (LDPE) is the most flexible, with high-density, high-molecular weight
formulations being least flexible. Moisture resistance is excellent. Properly formulated PE
has excellent weather resistance. The dielectric constant is 2.3 for solid and 1.6 for cellular
(foamed) insulation. Flame retardant formulations are available, but they tend to have poorer
electrical properties.
b) Polypropylene (PP):
Similar in electrical properties to polyethylene, this material is primarily used as an
insulation material. Typically, it is harder than polyethylene. This makes it suitable for thin
wall insulations. The UL maximum temperature rating may be 60°C or 80°C, but most UL
styles call for 60°C maximum. The dielectric constant is typically 2.25 for solid and 1.55 for
cellular designs.
c) Thermoplastic Elastomer (TPE):
TPE, sometimes called TPR (thermoplastic rubber), has excellent cold temperature
characteristics, making it an excellent insulating and jacketing compound in cold climates. It
is resistant to aging from sunlight, oxidation and atmospheric ozone. It retains most of its
physical and electrical properties in the face of many severe environmental conditions such
as a salt water environment.
TPE has good chemical resistance to all substances except hydrocarbons. It has a
tendency to swell in a hydrocarbon environment, causing the material to degrade. It has good
abrasion resistance. It will resist wear, cutting and impact. These properties make TPE
jackets an excellent choice for use in control cables that are dragged around or frequently
moved. TPE compounds are used as insulating materials up to a 600-volt rating.
d) Polyurethane (PUR):
Polyurethane is used primarily as a cable jacket material. It has excellent oxidation,
oil and ozone resistance. Some formulations also have good flame resistance. It has excellent
abrasion resistance. It has outstanding “memory” properties, making it an ideal jacket
material for retractile cords.
Thermoset Materials:
Thermosets are highly cross-linked polymers that have a molecular mesh or network of polymer
chains like a three-dimensional version of a net. Thermosets undergo a chemical as well as a
phase change when they are heated. Once cured they cannot be melted or remolded and are
resistant to solvents - that is once they are formed they are 'set' (hence the name).

Types And Applications:

1. Epoxi or Depoxi Resins:-
Epoxy is the cured end product of epoxy resins, as well as a colloquial name for the
epoxide functional group. The term epoxy has been widely adapted for many uses beyond
fiber reinforced polymer composites. Today, epoxy adhesives are sold in local hardware
stores, and epoxy resin is used as the binder in counter tops or coatings for floors. The
myriad of uses for epoxy continues to expand, and variates of epoxies are constantly being
developedto fit the industries and products they are used in.
Epoxy resins are commonly used in:
 General purpose adhesives
 As the binder in cements and mortars
 Rigid foams
 Non-skid coatings
 Solidifying sandy surfaces in oil drilling
 Industrial coatings
 Potting and encapsulating media
 Fiber reinforced plastics

When compared to other traditionalthermoset or thermoplastic resins, epoxy resins have

distinct advantages, including:
 Low shrink during cure
 Excellent moisture resistance
 Excellent chemical resistance
 Good electrical properties
 Increased mechanical and fatigue strength
 Impact resistant
 No VOCs
 Long shelf life

2. Urea Formaldehyde
Urea formaldehyde resin is a highly crosslinked thermosetting polymer primarily
made up of urea and formaldehyde with formaldehyde acting as the crosslinker. The urea-
formaldehyde reaction is acid curing and heat accelerated for forming a rigid, crystalline-like
polymer. Urea resins are noted for their fast cure, high strength and cost effectiveness. Due to
their reactive nature, UF resins are some of the fastest curing resins available. At high
temperature, they can be cured in as little as 2 seconds.
Urea formaldehyde resins are stable, fast curing and highly customizable making them an
excellent choice for a wide array of applications, some of which are:
 Wet laid fiberglass mat
 Decorative laminates
 Air filtration
 Coated and bonded abrasives
  Wood composites

3. Formica
Formica was created back in 1913 as a replacement "for mica" electrical insulation.
Early operations of the Formica Corporation revolved around electric motor v-rings. In 1927,
the Formica Corporation patented abarrier sheet; it was the first piece of what would soon
become the Formica kitchen and bathroom countertop revolution. "Formica " Laminate" is
made from two things: paper & resins. The papers are saturated with resins and dried, then
stacked and pressed under heat. In common use, the term Formica refers to the company's
classic product, a heat-resistant, wipe-clean, plasticlaminate of paper or fabric with melamine
resin.
By the 1950s, Formica laminates were everywhere, in bold and bright new colors. It
was featured everywhere from new homes to passenger train cars, and everybody wanted the
look and feel of laminates. Formica started as insulation and evolved into one of the most
widely used materials in the world.

4. BAKELITE:
Bakelite or polyoxybenzylmethylenglycolanhydride, is an early plastic. A hard,
infusible, and chemically resistant plastic, Bakelite was based on a chemical combination
of phenol and formaldehyde (phenol-formaldehyde resin), two compounds that were derived
from coal tar and wood alcohol (methanol), respectively, at that time. Because of its excellent
insulating properties, Bakelite was also the first commercially produced synthetic resin,
replacing shellac and hardrubber in parts for the electric power industry as well as in home
appliances.
In the 1920s it was widely used in knobs, dials, circuitry panels, and even cabinets
for radios, and it was also employed in the electrical systems of automobiles. In the 1930s
cast Bakelite, along with many other competing phenolic resins, enjoyed a vogue in colourful
costume jewelry and novelties. The primary commercial uses for Bakelite today remain in
the area of inexpensive board and tabletop games produced in China, India and Hong Kong.
Items such as billiard balls, dominoes and pieces for games like chess, checkers,
and backgammon are constructed of Bakelite for its look, durability, fine polish, weight, and
sound. Common dice are sometimes made of Bakelite for weight and sound.
5. SIR (silicon rubber):
Silicone rubber is an elastomer (rubber-like material) composed of silicone—itself
a polymer—containing silicon together with carbon, hydrogen, and oxygen. Silicone rubbers
are widely used in industry, and there are multiple formulations. Silicone rubber is generally
non-reactive, stable, and resistant to extreme environments and temperatures from -55 °C to
+300 °C while still maintaining its useful properties. Silicones resist acids, bases, solvents,
chemicals, oils and water. Due to these properties and its ease of manufacturing and shaping,
silicone rubber can be found in a wide variety of products, including: automotive
applications; cooking, baking,and food storage products; apparel such as undergarments,
sportswear, and footwear; electronics; medical devices and implants; and in home repair and
hardware with products such as silicone sealants.
With the addition of carbon or another conductive substance as a powdered filler,
silicone rubber can be made electrically conductive while retaining most of its other
mechanical properties. As such it is used for flexible contacts which close on being pressed,
used in many devices such as computer keyboards and remote control handsets.The dielectric
 insulating property of silicone is the best of any of the available elastomers. For example, a
half inch thick piece of silicone has the same dielectric properties as that of 18 inches of air.
Another useful benefit is that the dielectric and physical properties are not affected by
temperature extremes.
Examples of electrical engineering applications include:
- Cables and cable terminations
- Corona-resistant insulation tubing
- Keyboards and contact mats
- Conductive profiled seals

 TYPES OF SIR:
1) HTV(high temperature Volcanized)
2) RTV(room temperature vulcanized)
3) LSR(liquid silicon rubber)

6. XLPE(cross-linked polyethylene):
Cross-linked polyethylene, is a form of polyethylene with cross-links. It is formed
into tubing, and is used predominantly in building services pipework systems, hydronic
radiant heating and cooling systems, domestic water piping, and insulation for high
tension (high voltage) electrical cables. It is also used for natural gas and
offshore oil applications, chemical transportation, and transportation of
sewage and slurries.

Comparison of Thermoset and Thermoplastic Materials:

References:

[1] http://www.britannica.com
[2] http://en.wikipedia.org/wiki/Ceramic_materials
[3] http://jersey.uoregon.edu/~mstrick/AskGeoMan/geoQuerry34.html
[4] http://www.galleries.com/Talc
[5] http://www.clayheritage.org/pages/whatisballclay.htm
[6]https://corpapps.anixter.com/DocLib1/F11EK5NE/$file/thermosetvsthermoplasticJune
2010.pdf
[7]https://www.anixter.com/content/dam/Anixter/Guide/7H0011X0_W%26C_Tech_Han
dbook_Sec_03.pdf
[8]https://myelectrical.com
[9]Thermoplastic elastomeric (TPE) materials and their use in outdoor electrical
insulation Salman Amin and Muhammad Amin (March 03, 2011)
[10]http://composite.about.com/od/Resins/a/Epoxy-Resin.htm
[11]http://www.momentive.com/
[12]http://home.howstuffworks.com/home-
improvement/construction/materials/formica.htm
[13] http://www.britannica.com/EBchecked/topic/49449/Bakelite