High Voltage Electrical Epoxy Insulation Solutions

In modern power systems, the reliability and longevity of high-voltage apparatus (such as Gas Insulated Switchgear (GIS), current/voltage transformers, and insulators) are paramount. Among these, epoxy resin vacuum casting potting technology plays an indispensable role. It is a core manufacturing process that ensures these critical components possess superior electrical insulation, robust mechanical strength, and long-term operational stability.

What is Epoxy Resin Vacuum Casting Potting?

Epoxy resin vacuum casting potting is a process conducted in a vacuum environment, where a specifically formulated epoxy resin compound is poured into a mold containing electrical components (such as coils and cores). The resin permeates, encapsulates, and subsequently cures to form a solid, integrated structure.

The process primarily involves three key steps:

1. Pre-treatment and Mixing:The raw materials, including epoxy resin, hardener, and fillers, are preheated, dehydrated, and precisely mixed at specific temperatures.

2. Vacuum Casting:The mixed resin compound is slowly poured into the mold within a high-vacuum environment. This vacuum effectively removes air bubbles from the mold cavity and the material itself, preventing the formation of voids or defects.

3. Curing and Demolding:After pouring, the component undergoes a curing reaction following a strictly controlled temperature profile, ultimately forming a dense, complete three-dimensional solid network structure before being demolded.

Why is Vacuum Casting Preferred for High-Voltage Apparatus?

Compared to atmospheric pressure potting, the vacuum casting process represents a qualitative leap, with its core advantages being:

• Ultimate Insulation, Eliminating Partial Discharge:Air bubbles are the "archenemy" of insulation, easily triggering partial discharge under high-voltage electric fields, which leads to insulation aging and breakdown. The vacuum environment thoroughly eliminates bubbles, creating a defect-free, dense insulator with extremely high dielectric strength and excellent resistance to partial discharge.

• Superior Thermal Management and Mechanical Protection:The cured epoxy offers excellent thermal conductivity, aiding in heat dissipation from internal components. Simultaneously, it provides robust mechanical support as an integrated structure, offering resistance to vibration and shock, and protecting internal delicate parts from moisture, chemicals, and mechanical stress.

• Integrated Structure, Enhanced Reliability:The epoxy resin exhibits strong adhesion to embedded parts (such as conductors and electrodes), forming a seamless, integrated structure. This eliminates relative displacement between components, significantly enhancing the overall mechanical stability and long-term operational reliability of the equipment.

• Design Flexibility, Adapting to Complex Structures:The liquid resin can perfectly fill every corner of the mold, making it highly suitable for casting insulation parts for high-voltage apparatus with complex internal or irregular geometries.

Primary Application Areas

This technology is widely used in various high-voltage and ultra-high-voltage power equipment:

• Gas Insulated Switchgear (GIS):GIS basin insulators, insulating rods, etc.

• Instrument Transformers:Coil potting for current transformers and voltage transformers.

• Dry-Type Transformers:Insulation and encapsulation of transformer windings.

• Insulators and Bushings:Various high-voltage support insulators and wall bushings.

Choose Us, Choose Reliability

As a leading provider of high-voltage insulation solutions, we possess advanced epoxy resin vacuum casting equipment, a professional material R&D team, and a stringent quality control system. We deeply understand the demanding insulation requirements of high-voltage apparatus and are committed to providing customers with a one-stop vacuum casting solution—from material formulation and mold design to process optimization. We ensure your products operate stably in demanding grid environments, creating greater value.

Contact us to empower your next-generation high-voltage apparatus with a reliable "Insulation Core"!