Insulation materials used in Medium and High Voltage Switchgear (12kV–40.5kV) can be broadly classified into laminated insulation materials, insulation support components, flexible insulation materials, cast resin insulation components, molded insulation components, and specialty insulation materials. These materials play critical roles in electrical insulation, mechanical support, arc resistance, tracking resistance, and high-temperature protection, ensuring the safe and reliable operation of switchgear systems.

| Material Name | Grade | Thermal Class | Key Characteristics | Typical Applications |
|---|---|---|---|---|
| Epoxy Glass Fiber Laminate | G10 | Class B (130°C) | High mechanical strength and excellent electrical insulation | Insulating spacers, supports, barriers |
| Flame-Retardant Epoxy Glass Laminate | FR-4 | Class B/F (130–155°C) | Flame-retardant and self-extinguishing | Structural insulation components, barriers |
| High-Temperature Epoxy Glass Laminate | G11 | Class H (180°C) | Excellent heat and moisture resistance | High-temperature insulation parts |
| Glass Mat Reinforced Polyester Laminate | GPO-3 | Class F (155°C) | Superior arc resistance and tracking resistance | Busbar support plates, insulation barriers |
| Phenolic Cotton Cloth Laminate | 3025 | Class E (120°C) | Good toughness and excellent machinability | Insulation support components |
| Phenolic Paper Laminate | 3021 | Class A (105°C) | Cost-effective with stable electrical insulation properties | Auxiliary low-voltage insulation components |
| Product Name | Material Composition | Primary Function |
|---|---|---|
| Post Insulator | Epoxy Resin | Supports busbars |
| Busbar Insulation Clamp | GPO-3 / SMC | Secures and insulates busbars |
| Insulation Barrier | GPO-3 / FR-4 | Phase-to-phase isolation |
| Insulation Support Bracket | G10 / G11 | Structural support |
| Insulating Sleeve | Epoxy Resin | Conductor pass-through insulation |
| Material Name | Construction | Thermal Class | Main Applications |
|---|---|---|---|
| DMD Insulation Paper | Polyester Film + Polyester Nonwoven Fabric | Class B (130°C) | Secondary circuit insulation |
| NMN Insulation Paper | Nomex + Polyester Film + Nomex | Class H (180°C) | High-temperature insulation systems |
| NHN Insulation Paper | Nomex + PPS Film + Nomex | Class H (180°C) | Premium switchgear insulation systems |
| Polyester Film | PET Film | Class B (130°C) | Conductor wrapping insulation |
| Polyimide Film | PI Film | Class H (220°C) | Special high-temperature insulation applications |
| Switchgear Section | Commonly Used Insulation Materials |
|---|---|
| Busbar Compartment | GPO-3, FR-4, Epoxy Post Insulators |
| Circuit Breaker Compartment | Epoxy Contact Boxes, SMC Insulation Components |
| Cable Compartment | Epoxy Bushings, G10 Laminates |
| Secondary Control Compartment | DMD, NMN, PET Film |
| Busbar Connection Area | GPO-3 Insulation Barriers, FR-4 Spacers |
| Current Transformer (CT) | Epoxy Resin, NMN Insulation Paper |
| Voltage Transformer (VT/PT) | Epoxy Cast Resin Components, DMD Insulation Materials |
| Application Function | Mainstream Material |
|---|---|
| Busbar Support | GPO-3 |
| Insulation Barrier | FR-4, GPO-3 |
| Post Insulator | APG Cast Epoxy Resin |
| Contact Box | APG Cast Epoxy Resin |
| Insulating Cover & Housing | SMC |
| Secondary Insulation | DMD, NMN |
| High-Temperature Areas | G11, NMN |
In the 12kV–40.5kV medium-voltage switchgear industry, GPO-3, FR-4, APG cast epoxy resin components, and SMC molded insulation parts have become the mainstream insulation solution.
Among these materials:
GPO-3 is widely used for busbar supports and insulation barriers due to its excellent arc resistance, flame-retardant performance, and tracking resistance.
FR-4 is commonly utilized for precision-machined structural insulation components because of its superior electrical and mechanical properties.
SMC molded insulation components are extensively used in insulation covers and enclosures because of their excellent flame resistance, mechanical strength, and moisture resistance.
APG cast epoxy resin components are the core materials for contact boxes, bushings, and post insulators, offering high dielectric strength and dimensional stability.
As the demand for renewable energy substations, smart grid infrastructure, and advanced power distribution systems continues to grow, the adoption of G11 high-temperature laminates and NMN Class H insulation materials is steadily increasing, driven by the need for enhanced thermal performance and long-term operational reliability.
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