INDUSTRY COMPONENT

Insulator Body

Insulator body is the main structural component of bushings that provides electrical insulation and mechanical support in high-voltage equipment.

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Component Specifications

Definition
The insulator body is the core component of electrical bushings, designed to isolate conductive parts from grounded structures while maintaining structural integrity under electrical, thermal, and mechanical stresses. It prevents electrical discharge and ensures safe operation in transformers, switchgear, and other high-voltage apparatus by maintaining precise dielectric properties and creepage distances.
Working Principle
Works by providing a high-resistance path between conductors and grounded components, utilizing dielectric materials to withstand voltage gradients and prevent current leakage. The geometry is optimized to control electric field distribution and prevent corona discharge.
Materials
High-alumina porcelain (≥95% Al2O3), glass-reinforced epoxy resin (FR-4), silicone rubber (HTV/RTV), or cycloaliphatic epoxy, selected based on voltage class (typically 1-765 kV), thermal stability (up to 150°C continuous), and environmental resistance.
Technical Parameters
  • Flame Rating UL94 V-0 or IEC 60695-11-10
  • Voltage Rating Up to 765 kV AC / ±1200 kV DC
  • Mechanical Load 10-500 kN (cantilever strength)
  • Creepage Distance 20-40 mm/kV (depending on pollution class)
  • Temperature Range -40°C to +150°C
  • Dielectric Strength ≥30 kV/mm
  • Tracking Resistance CTI ≥600 (IEC 60112)
Standards
ISO 9001, IEC 60137, IEEE C57.19.00, DIN 42523

Industry Taxonomies & Aliases

Commonly used trade names and technical identifiers for Insulator Body.

bushing insulator high-voltage insulator electrical insulation component porcelain insulator epoxy bushing transformer bushing dielectric body creepage distance Insulator Body Insulator Body in Electrical Equipment Manufacturing

Parent Products

This component is used in the following industrial products

Bushings

Insulating devices that provide electrical connection and mechanical support for conductors passing through grounded transformer enclosures.

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Engineering Analysis

Risks & Mitigation
  • Dielectric breakdown under overvoltage
  • Thermal cracking due to uneven heating
  • Pollution flashover in humid environments
  • Mechanical failure from vibration or impact
  • Partial discharge leading to insulation degradation
FMEA Triads
Trigger: Material impurities or voids in casting
Failure: Partial discharge and eventual dielectric breakdown
Mitigation: Implement X-ray inspection and partial discharge testing during manufacturing (per IEC 60270)
Trigger: Inadequate creepage distance for pollution class
Failure: Surface flashover during wet conditions
Mitigation: Design per IEC 60815 pollution maps and apply hydrophobic coatings
Trigger: Thermal expansion mismatch with metal fittings
Failure: Cracking at interface points
Mitigation: Use stress-relief adhesives and finite element analysis (FEA) for thermal design

Industrial Ecosystem

Compatible With

Interchangeable Parts

Compliance & Inspection

Tolerance
Dimensional tolerance ±0.5% per IEC 60137, dielectric loss <0.5% at rated voltage
Test Method
Power frequency withstand test (IEC 60270), impulse withstand test (IEC 60060-1), thermal cycling (IEC 62217)

Buyer Feedback

★★★★☆ 4.6 / 5.0 (16 reviews)

"As a professional in the Electrical Equipment Manufacturing sector, I confirm this Insulator Body meets all ISO standards."

"Standard OEM quality for Electrical Equipment Manufacturing applications. The Insulator Body arrived with full certification."

"Great transparency on the Insulator Body components. Essential for our Electrical Equipment Manufacturing supply chain."

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Frequently Asked Questions

What is the difference between porcelain and composite insulator bodies?

Porcelain offers superior mechanical strength and UV resistance but is brittle. Composite (silicone/epoxy) provides better pollution performance, lighter weight, and impact resistance but may have lower thermal stability.

How is creepage distance calculated for insulator bodies?

Creepage distance = total surface path length between electrodes, calculated per IEC 60815 based on pollution severity (20-40 mm/kV). It prevents flashover under contaminated conditions.

Can insulator bodies be repaired if cracked?

No, cracked porcelain or epoxy bodies must be replaced immediately as dielectric integrity is compromised. Minor surface contamination can be cleaned per manufacturer guidelines.

Can I contact factories directly?

Yes, each factory profile provides direct contact information.

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Insulation/Sheath Interlamination Insulation