Polymer Compounds

Used In High Voltage

Insulators
by

R. Allen Bernstorf
Principal Engineer Insulators

Randall K. Niedermier
Manager
Polymer Development

David. S. Winkler
Polymer Chemist

of

Hubbell Power Systems

The Ohio Brass Company

POWER SYSTEMS, INC.

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POLYMER COMPOUNDS USED IN HIGH VOLTAGE INSULATORS

Introduction
Since their introduction in the early 1970s, polymer insulators have been increasingly accepted by
utilities as suitable replacements for porcelain and glass insulators. This paper presents details to
the non-chemist on the types of polymers used in compounds for high voltage insulation.
The polymers that will be discussed are ethylene propylene polymers, which include ethylene
propylene rubber (EPR) and ethylene propylene diene monomer (EPDM), silicone rubber (PDMSO)
and an alloy of EPDM and PDMSO.

Polymer Composition
A polymer is composed of very large molecules. Each molecule contains atoms arranged one
after another in a chain-like manner. The chain-like arrangement repeats in regular cycles, so the
structure can be written as certain segments which repeat n times [1]. Each polymer is commonly named after the raw material used to make it. For example:

n C=C
H

HCH

HCH

[C C]n
H

H
H

n C=C

H
Ethylene

n C=C
H

Polyethylene

Ethylene

Propylene

HCH

HCH
H

mC = C
H

Propylene

Polypropylene

H
H
+

[C C]n

[C C]n [C C]m
H
Ethylene

Propylene Rubber

Chemical Structures [2]

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H
HCH
n Cl Si Cl

H
HCH

H
HCH

+ 2H2 O n HO Si OH + 2 HCL [Si O]n

HCH
H
Dimethyldicloro
Siloxane

HCH
H
Dimethylsilane diol

HCH
H
Polydimethyl
siloxane

The word polymer is Greek for many parts , thus polyethylene translates to many ethylenes .
The n and m are a measure of the molecular weight of the polymer . Typically, when n and m
are small (low molecular weight) the polymer exhibits low physical properties and in some cases it
may be a liquid. As n and m increases (molecular weight increases), the polymer s physical
properties are improved [3]. As mentioned above, polymers are very large molecules, where in
the case of EPR, the n and m can be as high as 1,000,000 [4]. In the case of silicone rubber n
is in the range of 3,000 to 10,000 [5].
EPR is normally manufactured in a continuous process in large reactors. The monomers, ethylene, propylene and sometimes a diene (in the case of EPDM), along with the catalyst are metered
into the reactor and the polymerization takes place almost instantly at room temperature. After
polymerization, the polymer is cooled, dewatered, dried, cooled again and compressed into bales
[6]. The EPR polymer is now ready for compounding (#).
In comparison, silicone rubber is usually manufactured from the direct process of methyl chloride
and elemental silicon. One of the by products of this process is not stable and condenses with the
evolution of water to form a mixture of polydimethylsiloxanes of low molecular weight. Once separated, they are polymerized to higher molecular weight in the presence of catalysts [7]. Now the
silicone rubber is ready for compounding (#).
(#) - Once the polymer has been manufactured, it needs to be compounded into a suitable
material for use in high voltage insulators. Polymer compounding is the science of mixing
the polymers discussed above, with other chemicals to produce a polymer compound
which has specific properties for an application. Examples of polymer compounds could
be chewing gum, a garden hose, tires, solid rocket fuel, and of course, electrical insulators. Polymer compounding will be discussed in more detail in a later section.

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Comparison of Polymers in Use Today

EPR
EPRs are among the best weathering resistant synthetic polymers [8]. Because of EPR s saturated polymer backbone (*) it has excellent electrical, chemical and mechanical properties with
superior aging and color stability. In general all EPRs have outstanding resistance to heat, oxygen, ozone and sunlight. In fact, the resistance of EPDM rubber to sunlight is rated equal to that
of silicone rubber [9], [10], [11].
There are a variety of EPM and EPDM polymers available today, each offering different combinations of characteristics. The selection of a particular polymer has to be made on the basis of a
thorough evaluation of the characteristics and their significance for the intended application.
Silicone Rubber
As shown on the previous page, silicone rubber contains a repeating silicon-oxygen backbone
and has organic methyl groups attached to a significant proportion of the silicon atoms by siliconcarbon bonds [12]. Silicone rubber is classified as an organo-silicon compound [13]. This is due
to the very important bond between carbon (organic) and silicon (inorganic) [14]. Silicone rubber
is not inorganic.
Because of the silicon-oxygen backbone, silicone rubber is resistant to sunlight, heat and is
flexible over a wide range of temperatures. But, unlike the EPR backbone, the silicon-oxygen
bond is susceptible to heterolytic cleavage, i.e., attack by acids and bases [15]. Silicone rubber
has low physical properties compared to EPR based materials [16]. Silicone rubber is a hydrophobic material (repels water). This is due to the organic groups attached to the silicon atom. Silicone
rubber is also over 10 times more permeable to moisture than EP rubber.
As is the case for EPRs, many different silicone polymers are commercially available, but relatively few are suitable for high voltage applications. Extensive evaluation, analysis and testing are
required to ensure an appropriate match of material characteristics with application needs.
EPDM/Silicone Alloy
Recognizing the only beneficial characteristic of silicone rubber - hydrophobicity - but desiring a
compound which had the excellent mechanical properties that EPDM can provide, Ohio Brass
developed an alloy of EPDM and silicone which combines the best properties of these two materials. This compound is called ESP.
(*) Backbone refers to the C-C chain found in EPR materials and the Si-O found in silicone.

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Compounding
In the field of polymer technology, rubber compounding is a complex subject. Compounding is
part art, part science. The compounder s ability to select and combine polymers and additives to
obtain a mixture that will develop the necessary physical and chemical properties can take years
to master [17].
A practical compound formulation can consists of 10 or more ingredients. Each ingredient has a
specific function and each has an impact on properties and processibility.
The remainder of this section will be dedicated to brief descriptions of the ingredients and their
functions.
Elastomers
As discussed in previous details, the most important step in compounding is the selection
of the elastomer, or base polymer. The selection of an elastomer should be based on the
properties desired and processibility of that elastomer.
Vulcanizing Agents
Vulcanizing agents are ingredients used to cause a chemical reaction, resulting in the
cross-linking of elastomer molecules. Through chemical cross-linking, an elastomeric compound is converted from a soft, tacky material to a stiff, temperature-stable material. There
are many types of vulcanizing or curing agents used. Organic peroxides are the most
widely used for high voltage insulation.
Coagents
Coagents protect the already cross-linked bonds between the polymer and vulcanizing
agent from being torn apart. This assures that bonds are not broken as fast as new bonds
are generated.
There are two types of coagents: type I and type II. Type I coagents increase the cure rate
(speed) and cure state (stiffness) of the compound. Type II coagents increase the cure
state but do not effect cure rate.
Antidegradants
Antidegradants are used to retard the deterioration of a rubber compound initiated by oxygen, ozone, heat and light.
In the selection of antidegradants the following factors must be considered:
1. type of protection desired
2. chemical activity
3. persistence (volatility and extractability)
4. discoloration and staining

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Processing Aids
Processing aids are added to a rubber compound to help mold flow and release, as well as
aid in the mixing of the compound.
Fillers
Fillers are used to reinforce the base elastomer which can increase the physical properties
or impart certain processing characteristics. There are two types of fillers: reinforcing and
extending.
The reinforcing type can improve tensile strength, modulus, tear strength and abrasion
resistance of a compound.
An extending filler is a loading or non-reinforcing material. It may be used to impart some
desirable property. Alumina trihydrate (ATH) is used in nearly all insulator compounds to
impart a high resistance to electrical tracking and inflammability.
Coupling Agents
A coupling agent provides a chemical bond between the filler and the elastomer. The coupling agent is a bridge between the ATH and the polymer. This can greatly improve the
electrical properties, modulus and tensile strength.
Plasticizers and Softeners
Plasticizers and softeners are used to either aid mixing, modify viscosity or provide flexibility at low temperatures. Many ingredients in this group may also be considered as processing aids.
Special Purpose Materials
Special purpose materials are used for a specific purpose which is not normally required in
the majority of rubber compounds. Antifungal agents, blowing agents, colorants, re-odorants, the Ohio Brass silicone material and materials which assist the compatibilization of
silicone to the matrix are examples of special purpose materials.

Formulation Testing/Material Characterization

Polymer insulating materials are typically formulated to provide performance characteristics equivalent to, or better than that of porcelain. Because of the different physical properties of porcelain
and polymers, a comparison is usually made only on short term electrical characteristics of complete insulators - e.g. wet and dry 60 Hz flashover, critical impulse flashover. However, many
physical properties of a polymer material must be understood and properly controlled to give the
material the characteristics necessary to serve a long life as a high voltage insulating polymer.
Once a compound has been formulated to meet the desired criteria, various types of design tests
are conducted. These tests ensure the formulation exhibits the required characteristics for use in
high voltage insulators.

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Comparison of Polymer Compounds in Use Today

The materials discussed in the following testing section are commercially available rubber
compounds designed for high voltage insulators. The EPM compound is the original Ohio
Brass compound. The EPM/Silicone alloy is the original Ohio Brass with silicone added. ESP is
the current Ohio Brass compound which is an EPDM with silicone added.
Again, the other compounds listed are commercially available for any insulator manufacturer to
purchase.

Design Tests
While there are several standardized (e.g. ASTM, ANSI, CEA CSAN, IEC) tests to evaluate insulating materials, few of these are particularly suited to proper assessment of the characteristics
required for outdoor high voltage insulation. As a consequence, Ohio Brass developed specialized
tests for evaluating materials for its polymer insulator products.
A polymer compound s suitability for long term use in high voltage insulators is assessed by means
of design tests. By necessity, given that an insulator s lifetime is measured in decades, design
tests involve accelerated aging or conditioning.
Good polymer compounds used for high voltage insulation should be tested for the ability to resist
tracking, erosion, corona, oxidation and ultra-violet (UV) radiation exposure.

Tracking Test
The tracking resistance of a compound is a measure of its ability to withstand intense leakage
currents combined with dry band arcing. The dry band arcing generates ozone, high temperature
and UV radiation exposure on the polymer surface. Test conditions vary among laboratories, but
typically samples of the compound are wetted with a conducting solution and then energized in a
circuit with a controlled current. Samples are then evaluated in terms of the number of cycles or
time to failure. Acceptable performance is dependent upon materials and test methods. Good
compounds will survive for tens of thousands of cycles.
A polymer compound must exhibit excellent resistance to tracking and erosion. Polymers degrade
by erosion and tracking due to the heat generated by leakage currents and dry band arcing. Since
each polymer differs in terms of tracking resistance, one of the ways to differentiate various compounds is to subject them to a tracking test.
The Ohio Brass tracking test was designed to evaluate glaze compounds for porcelain insulators.
It was used next for evaluating the tracking and erosion resistance of polymeric insulating materials. This test evaluates the relative ability of an insulating material to withstand electrical discharges on the surface which are similar to those that may occur in service under the influence of
dirt, moisture and conducting salts condensed from the atmosphere.
Samples are mounted on a 30 degree incline with electrodes attached on either side. The electrodes are positioned 35 mm apart. The samples are cyclically sprayed with a conductive solution

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and then energized. Each cycle is 90 seconds. The conductive liquid has a resistivity of about 400
ohm-cm and is formulated to leave no residue on the sample s surface. A voltage of 10 kV is
applied with a controlled current of 20 mA. The leakage current and subsequent dry band arcing
dry the surface of the sample. Test results obtained from the tracking test provide a means of
comparatively ranking the tracking resistance of materials.
Failure is judged by one of three criteria:
1. carbonization or tracking of the sample s surface;
2. the sample remains conductive at the end of the 90
second cycle; or
3. erosion creates a hole in the sample.
MATERIAL
Porcelain
EPM
EPM/Silicone Alloy
ESP
Silicone Rubber1
EPDM1

CYCLES
50,000
50,000
22,700
50,000
16,000
1,800

COMMENTS
No Failure
No Failure
Failure
No Failure
Failure
Failure

Table 1. Tracking Test Results

Silicone Rubber1 and EPDM1 are commercially available insulating compounds.

Ultra Violet
Polymer insulating compounds are exposed to UV radiation not only from sunlight, but also from
corona and dry band arcing. Resistance to degradation resulting from ultra violet (UV) exposure is
an important factor in determining the service life of a polymer.
The energy from sunlight that is destructive to polymers is between 320 and 270 nanometers.
This destructive energy constitutes less than five percent of the total radiation reaching the surface of the planet. The absorption of this UV radiation results in mechanical and chemical degradation of the polymer structure which can affect the dielectric and weathering properties of that
polymer. The rate at which the degradation occurs is dependent upon the intensity and wavelength of the radiation. These factors vary with season, time of day, elevation and latitude. Acceleration of the effects occurs in the presence of moisture on the polymer s surface. Polymer compounds for use in outdoor environments should, therefore, be evaluated in the combined presence
of UV radiation and high humidity.
An accelerated evaluation can be performed in a Weatherometer or QUV tester. Ohio Brass believes the QUV test to be the most meaningful test for outdoor insulation. Through comparisons
with tests performed at the Desert Sunshine Exposure Test (DSET) site in Arizona, the aging
acceleration of the QUV test has been assessed as 8:1; that is one hour of QUV test is equivalent
to eight hours of exposure in the Arizona desert, which is considered one of the most severe
natural UV environments in North America.

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The negative effects of UV radiation for a polymer include:

1. crazing, checking or cracking of the surface
2. loss of hydrophobicity
3. discoloration.
The QUV test is an accelerated weathering test performed in conformance to ASTM G53. The
QUV test alternates UV radiation exposure and condensation during each cycle. A cycle consists
of 8 hours of condensation and 16 hours of UV exposure.
The QUV test simulates the effects of sunlight by means of fluorescent UV lamps positioned within
inches of the test specimen. A water reservoir at the bottom of the test chamber is heated to
produce vapor. The hot vapor keeps the chamber at 100% relative humidity. The water vapor
condenses on the cooler surfaces of the test specimens. The combination of condensation with
high intensity UV radiation results in an accelerated exposure test.
Under accelerated testing methods, like ASTM G53 (QUV), a good polymer compound should be
capable of sustaining 10,000 hours of exposure without crazing, cracking or displaying any loss of
hydrophobicity. However, loss of hydrophobicity does not indicate the end of life for a polymer
compound. The test results obtained from the QUV test provide a means of comparatively ranking
the UV resistance of materials. Such results are listed in Table 2.
MATERIAL
EPM
EPM/Silicone Alloy
ESP
EPDM1
EPDM2
Silicone Rubber1

TIME, HRS
8,000
8,500
36,500
1,000
4,000
39,000

COMMENTS
Loss of Hydrophobicity
Loss of Hydrophobicity
Still Hydrophobic*
Checking of Surface
Loss of Hydrophobicity
Still Hydrophobic*

Table 2. QUV Test Results *indicates ongoing test

EPDM1, EPDM2 and silicone rubber1 are commercially available insulating compounds from different manufactures.

Corona
Corona discharges form at the surface of an insulator when the electric field intensity on the
surface exceeds the breakdown strength of air, which is about 15 kV/cm. Corona generation is
dependent on atmospheric conditions such as air density, humidity, and geometry of the insulator.
The effects of corona are radio interference, TV interference, noise generation, ozone production,
and energy loss.
Corona accelerates the aging of polymers, by generating ozone and UV light. The UV light produced is of short wavelengths and includes the spectra of light damaging to polymers. The electric
discharge subjects the insulator to severe electrical strain and chemical degradation. Continued
degradation may render the polymer unusable. A polymer must be able to withstand this chemical

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degradation throughout its service lifetime. Electrical insulation that may be subject to corona
must be made from a properly compounded EPR or silicone rubber.
The presence of corona combines UV and heat with a high level of ozone. The Ohio Brass corona
cutting chamber combines this with mechanical stress to accelerate the degradation of a polymer.
Polymer insulator samples are subject to a mechanical stress of approximately 300,000 microstrain
by bending the sample over a grounded electrode.
Corona is continuously generated by applying 12 kV to a needlelike electrode placed 1 mm above
the strained surface of the sample. Under a combination of stress and continuous surface corona,
an unaged polymer should be capable of surviving for at least 1,000 hours without cracking, splitting, cutting or electrical failure. The test can be conducted surface corona, an unaged polymer
should be capable of surviving for at least 1,000 hours without cracking, splitting, cutting or electrical failure. The test can be conducted under dry air or with controlled humidity. The test is usually
run until failure of the sample. The cumulative time to failure is recorded. This test is used for
relative comparison. The test results are listed in Table 3.
MATERIAL
EPM
EPM/Silicone Alloy
ESP
EPDM2
Silicone Rubber1
Silicone Rubber2

TIME, HRS
404
1,290
3,250
2,780
348
1,650

COMMENTS
Failure
Failure
Test Terminated
Test Terminated
Failure
Test Terminated

Table 3. Corona Cutting Test Results

Silicone rubber1, silicone rubber2 and EPDM2 are commercially available insulating compounds
from different manufactures.

Oxidative Stability
Anti-oxidants are incorporated into a polymer compound to inhibit the attack of oxygen and ozone
on the compound s chemical composition. The effectiveness of an antioxidant is very important in
electrical insulation applications.
An oxidative stability test measures the time to deplete the anti-oxidants within a material under
controlled conditions. Oxidative stability is measured by using the thermal analysis technique of
differential scanning calorimetry (DSC). The DSC measures the amount of heat flowing into (endothermic) or out of (exothermic) the sample as a function of the material s temperature.
Oxidation is a highly exothermic process and is readily studied by DSC techniques. A test sample
is rapidly heated in a nitrogen atmosphere to the test temperature of 200C. The atmosphere is
then changed to oxygen and the temperature is maintained until the sample begins to oxidize.
When the sample oxidizes or decomposes, an exothermic reaction is registered. This indicates all
of the antioxidant has been consumed and the rubber sample is no longer protected. Good compounds typically exhibit oxidation in times greater than 400 minutes in oxygen at 200C. Typical
results are listed in table 4.

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MATERIAL
EPM
EPM/Silicone Alloy
ESP
EPDM1
EPDM2
Silicone Rubber1

TIME, MINUTES
20-26
400
400
20
400
400

COMMENTS
Failure
No Failure, End of Test
No Failure, End of Test
Failure
No Failure, End of Test
No Failure, End of Test

Table 4. Oxidative Stability Test Results

EPDM1, EPDM2 and Silicone Rubber1 are commercially available insulating compounds from different manufactures.
Ohio Brass first developed these test techniques in the mid 1960s for evaluating the characteristics of polymer insulating compounds, and over the intervening years has continued to improve
the methods. Twenty-five years of experience have indicated that materials which perform well in
these tests will offer decades of satisfactory service in field use.

Summary
This paper has presented details on the types of polymers used for high voltage insulators. There
are many factors which must be considered while designing a polymer compound for use as high
voltage insulation.

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References
1. The Vanderbilt Rubber Handbook, pp. 2. The Vanderbilt Company, Inc., Connecticut, (1990).
2. Fundamentals of Polymer Science, P.C. Painter, M.M. Coleman, pp. 24-25. Technomic Publishing Company, Inc. (1994).
3. The Vanderbilt Rubber Handbook, pp. 3. The Vanderbilt Company, Inc., Connecticut, (1990).
4. Science and Technology of Rubber, F.R Eirich, pp. 89-91. Academic Press, New York, (1978).
5. Rubber Technology, M. Morton, pp. 371. Van Nostrand Reinhold Company, New York, (1973).
6. The Vanderbilt Rubber Handbook, pp. 126-127. The Vanderbilt Company, Inc., Connecticut,
(1990).
7. Rubber Technology, M. Morton, pp. 370. Van Nostrand Reinhold Company., New York, (1973).
8. The Vanderbilt Rubber Handbook, pp. 234. The Vanderbilt Company, Inc., Connecticut, (1990).
9. Royalene EPDM Rubber Handbook, Comparative Property Chart, Uniroyal Chemical Company, Connecticut, (1988).
10. Basic Compounding and Processing of Rubber, pp. 6. Rubber Division, American Chemical
Society,Inc., The University of Akron, Akron, OH 44325, (1985).
11. Compounders Pocket Book - Chemicals for the Rubber Industry, pp. 189-190. Monsanto
Rubber Chemicals Division, Akron, OH 44313, (1981).
12. Concise Encyclopedia of Polymer Science and Engineering, pp. 1048. John Wiley and Sons,
Inc., New York, (1990).
13,14. Silicone Chemistry, J.L. Speier, M.J. Hunter, Reprinted from International Science and Technology, New York, (1963).
15. Concise Encyclopedia of Polymer Science and Engineering, pp. 1049. John Wiley and Sons,
Inc., New York, (1990).
16. Basic Compounding and Processing of Rubber, pp. 6. Rubber Division, American Chemical
Society,Inc., The University of Akron, Akron, OH 44325, (1985).
17. Basic Compounding and Processing of Rubber, pp. 6. Rubber Division, American Chemical
Society,Inc., The University of Akron, Akron, OH 44325, (1985).

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