Why Do Transformers Need Insulation? A Professional Analysis by A-TECH

Technical Library

In power systems and electronic devices, transformers are the core components for electrical energy conversion and voltage regulation. To ensure safe, stable, and efficient operation, insulation design plays an extremely critical role in transformers. This article will provide an in-depth analysis of the importance of insulation, common insulation methods, material temperature resistance ratings, and A-TECH's insulation system certification.

🎯 Why Do Transformers Need Insulation?

Transformers involve high voltage, high current, and high-frequency operating environments. Without proper insulation protection, short circuits, overheating, and even equipment damage can occur. The main reasons are as follows:

1. Prevents Short Circuits: Avoids internal wire short circuits
   If there is no proper insulation between windings, current will flow directly, causing a local short circuit, which may cause the transformer to burn out.
2. Prevents Electric Shock: Protects personnel safety
   The insulation layer can effectively isolate high-voltage electricity, preventing electric shock to operators or maintenance engineers.
3. Improves Efficiency: Reduces energy loss
   High-quality insulation materials can reduce leakage current, reduce energy loss, and improve transformer efficiency.
4. Withstands High Voltage and High Temperature: Ensures stable operation
   The insulation layer can withstand high-voltage impacts and resist long-term high-temperature operation, maintaining stable performance.
5.  Extends Lifespan: Prevents overheating and premature aging
   Insulation prevents heat concentration from causing winding aging, further extending the overall service life of the transformer.

🎯 Common Insulation Methods for Electronic Transformers

In the design of power transformers and electronic transformers, A-TECH adopts multi-layered insulation protection strategies to ensure that products meet international safety standards:

1. Enamelled Wire / Triple Insulated Wire
   • Using enamelled wire with high insulation performance can prevent short circuits between windings.
   • Triple insulated wire further enhances voltage resistance and is suitable for high-power and high-frequency applications.
2. Insulation Tape
   • Used to separate winding layers to prevent electric field breakdown.
   • Commonly used materials include polyester tape, polyimide tape, etc., which have high-temperature resistance characteristics.
3. Encapsulation
   • Encapsulating the transformer with epoxy resin or silicone enhances insulation and moisture resistance.
   • It also improves shock resistance and is suitable for industrial and automotive environments.
4. Impregnation
   • Immersing the windings in insulating varnish enhances voltage resistance and thermal stability.
   • Improves overall structural strength and reduces noise and vibration.

🎯 Temperature Resistance Ratings of Transformer Insulation Materials

Different insulation materials have different temperature resistance properties. Exceeding the material's tolerance range will lead to degradation of insulation performance, accelerated aging, and even failure. Therefore, the insulation class that meets the application environment must be selected when designing power transformers.

Insulation Class Maximum Operating Temperature Common Applications

• Y Class 90°C Low-power transformers
• A Class 105°C General power transformers
• E Class 120°C Consumer electronics
• B Class 130°C Industrial-grade power transformers
• F Class 155°C Automotive power supplies, high-power equipment
• H Class 180°C Extreme high-temperature environments and military applications

Note: If the operating temperature is close to the upper limit for a long time, the life of the transformer will be significantly shortened. Therefore, selecting the appropriate insulation class is a key design consideration.

🎯 A-TECH's Insulation System Certification

A-TECH has passed UL safety certification for its transformer insulation system, providing higher safety guarantees. Currently, the following two systems are mainly offered:

• Class B System (130°C)
  Suitable for general industrial applications, balancing stability and economy.
• Class F System (155°C)
  Suitable for high-power, high-frequency, and high-temperature environments, especially for automotive, medical, and industrial automation fields.

Through the UL-certified insulation system, A-TECH transformers can meet the stringent requirements of the international market for safety and reliability. A-TECH provides highly reliable insulation solutions for various electronic transformers and power transformers through rigorous insulation technology, carefully selected high-performance materials, and UL-certified systems, helping customers achieve more efficient, stable, and safe power applications.

👉 For more information about A-TECH solutions, please visit https://www.atechoem.com/tw/technology-detail/InsulationSystem/