POWERSIL® 1900 A/B: revolutionizing composite insulator manufacturing
WACKER presents its latest development in high-voltage engineering: POWERSIL® 1900 A/B. Truly a novelty that pushes the boundaries in the production of large-scale insulators, the special high-consistency silicone rubber allows manufacturers to implement the extrusion molding process to produce high-precision composite insulators at a comparatively low cost.
Set up your appointment at the K 2025 now.When power meets performance
To meet the challenges of driving forward with the energy transition and grid expansion, we need robust, durable, high-performance components – indeed, this also applies to insulators. To this effect, POWERSIL® 1900 A/B was specifically developed for applying the extrusion molding process for the production of composite insulators, in particular composite hollow-core insulators. Made up of a hollow, electrically non-conductive tube equipped with annular sheds on the exterior, composite hollow-core insulators are mainly used for electrotechnical equipment such as bushings and instrument transformers. In high-voltage applications, hollow-core insulators can be designed to have imposing dimensions – diameters of over one meter and lengths of up to ten meters are not uncommon. When it comes to such striking dimensions, one aspect is crucial: the weight.
Added power to a lightweight – thanks to POWERSIL® 1900 A/B
Composite hollow-core insulators stand out and, thanks to their comparatively low weight, are much easier to install than conventional insulators made out of ceramics. POWERSIL® 1900 A/B bestows even large-scale hollow-core insulators with variable diameters superior properties – in addition to weight savings of up to 80 percent.
Spiral extrusion techniques in production – it’s all about precision and cost efficiency
POWERSIL® 1900 A/B can be used in the production of hollow-core insulators by a special extrusion process known as spiral extrusion, whereby the silicone is extruded onto a continuously rotating insulating tube.
This ensures a thoroughly even application of the intricate insulating housing with its characteristic sheds. This process allows manufacturers to produce high-precision insulators at a comparatively low cost. Open curing of the silicone rubber in the furnace also facilitates the production of conical shapes that are otherwise often not feasible with conventional injection-molding techniques.
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A quick look at the advantages
Silicones in power engineering
Silicone elastomers have been a regular feature in high-voltage engineering for decades. As a high-performance insulating material, they possess numerous properties that no other material can match in this combination. The water-repellent surfaces of the cured elastomer are a typical feature of silicone elastomers. In particular, silicone elastomers are even able to impart this property to layers of dirt that may have deposited on the surface. This property, known in technical jargon as “hydrophobicity” or “hydrophobicity transfer”, prevents the formation of electrically conductive layers of water, dirt and salt, which can lead to electrical failure of the insulator due to flashovers. It is therefore no wonder that silicone rubbers are used today in virtually all areas of power transmission and generation.
This innovative 2K system is truly a milestone in hollow-core insulator manufacturing. The spiral extrusion process in particular facilitates the cost-effective production of even large-scale insulators with variable diameters.
- High degree of flexibility and design freedom
Easy to produce even large-scale and conical designs - Weight savings of up to 80%
For easier installation and reducing the load on the infrastructure - 2K silicone system, no by-products released during curing
The product cures by addition curing to form an electrically insulating silicone elastomer. - Excellent resistance to tracking and arcing
Highly safe even under extreme conditions - Lasting hydrophobicity
No need for cleaning operations in most applications; dirt and water simply drip off - Constant electrical insulation even when in continuous service
Not impacted by salty or dusty air or by moisture and rain - Excellent resistance to weathering and UV radiation
Resistant to temperature fluctuations, wind and rain - Exceptional elastic and mechanical strength
Long-term resistance to deformation, impacts and vibrations
POWERSIL® 1900 A/B – energy resilience for a sustainable future
POWERSIL® 1900 A/B cured rubbers are designed to withstand extreme environmental conditions for decades. Thanks to their elasticity, composite hollow-core insulators manufactured with POWERSIL® 1900 A/B can withstand all kinds of weather, earthquakes and vandalism far better than other materials.
Silicones thus improve power grid resilience and play an important role in ensuring a secure power supply – a key building block for a successful energy transition.
Experience POWERSIL® 1900 A/B live at the K 2025 International Trade Fair for Plastics and Rubber
Visit us from October 8 to 15 at the world's leading trade fair for the plastics and rubber industry in Düsseldorf. In Hall 6, Booth A10, discover how POWERSIL® 1900 A/B is revolutionizing the area of power grid expansion.
Set up your appointment at the K 2025 now.