Comparison of Dielectric Breakdown Voltages for Composites with Different

Resin Types

Dinesh kumar Dhunde 1, W. Elliott Hutchcraft 1, Richard K. Gordon 1, Ellen Lackey 2 and
James G. Vaughan 2
1 2
Department of Electrical Engineering, Department of Mechanical Engineering
University of Mississippi, University, MS 38677- 1848, USA
ddhunde@olemiss.edu, eeweh@olemiss.edu, eegordon@olemiss.edu, melackey@olemiss.edu and
mejgv@olemiss.edu

Abstract: The significance of dielectric breakdown voltage of different pultruded composites comprised
of unidirectional E-glass reinforcement with different matrix resins, denoted as epoxy / E-glass, polyester
/ E-glass, and phenolic/ E-glass which are often used as insulators is reported. For comparison, the
dielectric breakdown voltage of a polyurethane matrix composite with hybrid reinforcement of
unidirectional E-glass and basalt was also evaluated. A breakdown voltage measurement analysis was
done under both typical room temperature and humidity conditions and under moisture content
conditions. In a quasi-uniform field configuration, the breakdown was mainly governed by the major
flaws at the sample scale; this was demonstrated as the phenolic matrix sample that contained voids in the
matrix exhibited lower breakdown voltage than the composites with lower void content. The phenolic/E-
glass samples with the higher void content absorbed more water and, consequently, passed more current
during breakdown testing.

Keywords: Epoxy, polyester, polyurethane, phenolic, resin, dielectric breakdown voltage, composites,
flashover, corona, insulator, absorption, immersion, step-by-step rise, electrodes and voltage withstand.

1. Introduction

The safe operation of any electrical energy transmitting device depends on the reliability of its
components. Their reliability depends primarily on the performance of the insulating structures they
contain. At present time, due to the reduction of dimensions of the equipment and thenceforth the increase
of the heat density to be evacuated, the insulating materials should have the best possible initial properties
including a high dielectric breakdown voltage and thermo mechanical properties [1]. The dielectric
breakdown voltage is a very fast mechanism which is not preceded by any increase of the temperature.
The changing in the structure results directly from the action of the constraints due to the electric field.
Two theories have been proposed to explain the dielectric breakdown [2]. The first one (called “intrinsic
breakdown”) considers that the breakdown occurs when the instability of the electronic current appears in
the dielectric. According to the second theory (called “breakdown by avalanches”), the breakdown
criterion is assumed to be the electric field for which the electronic multiplication process reach
inadmissible proportions [2]. The material ceases to be a dielectric and then it becomes conducting.
Among the insulating materials, epoxy, polyester and polyurethane based composites are widely used due
to their ability to withstand high electric fields, which limits short-term breakdowns and the
environmental stresses that might lead to the initiation of partial discharges and electrical trees resulting
in the breakdown of the insulator. The partial discharges are the result of local enhancements of the
electrical field within the inclusions or gaseous cavities which can be present in the material. They appear
when the applied voltage reaches a threshold value corresponding to the Paschen minimum of the gas in
presence (air or others) [2]. Their action can lead to chemical and other radical transformations leading to
the failure of the material in consequence of mechanisms such as the propagation through the material of
microscopic channels, the cumulative heating due to the discharges. The partial discharge due to the
gaseous ionization leads to the initiation of electrical treeing [2]. Each irregularity (protrusion) at the
insulating wall (interface) of a cavity (void) favors the fast propagation of treeing and leads to the
breakdown. The partial discharges are linked to the electrical breakdown of composites, as a fact the
electrical tree growing initially in front of the electrode, leading to the creation of a channel. Then the
combination of electrical and thermomechanical stresses allows the tree to grow up to breakdown [3]. It
is therefore a major interest to understand and to predict the structural changes of these kinds of materials
and the influence of these changes on the dielectric strength. Polymeric composite materials such as the
ones tested in this study are used in a variety of applications requiring electrical insulation such as safety
ladders, tool handles, and equipment housing.

2. Breakdown Voltage Measurements

The tests were performed at room temperature under an ac voltage supplied by a 50 kV, 60 Hz
transformer. The breakdown voltages were determined as the average of three or four tests carried out in
contact mode in a step-by-step test [4]. The specimen was immersed in mineral oil to prevent surface
discharges and flashovers. The breakdown voltage measurements were performed under uniform fields,
respectively in cylinder/cylinder (Fig. 1) electrode arrangements.

Fig. 1. Basic Setup for Testing Fig. 2. Oil Bath with mineral oil for Testing

The electrodes were made of brass with a diameter of 25 mm, thickness of 25 mm and edges rounded to
3.2 mm for the 1 inch samples. Mineral oil whose breakdown voltage is approximately 26 kV/2mm was
used in the oil bath for reducing the effect of flashover [5]. Also gasket sealant which is a 100% silicone
material was used for sealing the electrode’s bottom in order to avoid sparks when high voltage is applied.
Under quasi uniform field, the electric field E associated to the electrical breakdown is calculated as
follow [3]:

V
            E=                                                                   (1)
d
The electric field mainly depends on the breakdown voltage and electrode gap. For the breakdown test, all
samples were cut by using a diamond blade to make sure that the samples were 2 inch long. The samples
were nominally 2 × 1× 0.125 inch. The specimens were also subjected to moisture conditioning according
to ASTM D570, by which we can determine the water absorption rate [6]. The samples were moisture
contained by immersing in boiling water for 120 ± 4 minutes. The weights were recorded using an
analytical balance capable of reading 0.0001 g, before and after the boiling process. The average percent
weight increase for each sample type is shown in Table 1.

Table 1. Average Percent Weight Increase for Samples after Moisture Conditioning

Resin System Average Average Standard Dev. Standard Average

conditioned wet weight (conditioned) (g) Deviation percentage weight
weight (g) (g) (wet) (g) increase

Epoxy 9.04 9.04 0.007 0.008 0.009

Polyester 1 9.1 9.11 0.005 0.005 0.108
Polyester 2 9.17 9.18 0.005 0.005 0.119
Phenolic 8.29 8.68 0.021 0.001 4.69
Polyurethane 8.69 8.69 0.107 0.107 0.007

Results and Discussions

Dielectric breakdown measurements are shown in Figures 3 and 4. These results demonstrate the
importance of the matrix of a polymeric composite and the importance of low void content. As seen in
Figure 3, the epoxy /E-glass composite and the polyester /E-glass composites had a significantly higher
breakdown field than did the phenolic /E-glass composite. As the example micrographs seen in Figures 5
and 6 show, phenolic matrix composites often exhibit higher void content than do similarly manufactured
polyester or epoxy matrix composites due to the nature of the curing reaction for the phenolic resin. It is
expected that the voids typically seen in such a phenolic matrix/E-glass composite contributed to the low
electric breakdown field for this type of composite. Manufacturing methods that resulted in polyester/E-
glass composites or epoxy/E-glass composites with high void content would also be expected to have a
lower breakdown field than a similar composite with a low void content. Therefore, it is seen that both
the constituent materials as well as the characteristics of the fabricated part must be considered when
describing the dielectric properties of composite materials.

The influence of moisture content on the electrical breakdown field and measured current of the materials
was evaluated to quantify the influence of changes due to moisture content. As seen in Figures 3 and 4,
significant differences were not seen in the breakdown field for these composites after moisture exposure;
however, significant differences were seen in the current for the phenolic/E-glass composite after
moisture exposure. The phenolic samples with the absorbed moisture passed significant current prior to
dielectric breakdown. Prior to moisture exposure, the initial current recorded for the phenolic/E-glass
composite was 0.1 mA and the current reached 1 mA at breakdown. After moisture exposure, the initial
current recorded for the phenolic/E-glass composite reached 22 mA and the current was 40 mA at
breakdown. According to OSHA, the human body can perceive current at 1 mA, a slight shock is felt at 5
mA, a painful shock can be felt from 6 – 30 mA, and current above 50 mA can cause extreme pain and
even death. It can be seen from Table 1 that the phenolic/E-glass samples absorbed significantly more
moisture during the 2 hour exposure to boiling water than the other composites. The relatively high void
content of the phenolic/E-glass composites allowed the water to more easily enter the phenolic/E-glass
samples. The low level of moisture absorption that occurred during the moisture exposure conditioning
of the polyester and epoxy samples, as shown in Table 1, explains why significant changes in dielectric
breakdown or current were not seen for these materials after the moisture exposure. This demonstrates
that longer term moisture exposure must occur before moisture absorption levels are sufficient to affect
dielectric breakdown voltage and current conduction for this type of polymeric composite material with
low void content.

As another comparison, a polyurethane matrix composite with unidirectional E-glass and basalt
reinforcement was also tested to evaluate the effect of the presence of the basalt fiber on the breakdown
voltage and current. Basalt fiber is formed from volcanic lava and offers somewhat better mechanical
properties than E-glass; however, basalt fiber is much less commonly used than E-glass. As seen in Table
1, the polyurethane/E-glass and basalt samples had very low moisture absorption. The moisture
absorption level was comparable to that of the epoxy/E-glass samples, and the breakdown voltages were
also similar to those of the epoxy/E-glass samples, with the breakdown field for the polyurethane/E-glass
and basalt samples averaging in the range of 8.4 kV/mm for samples without any moisture content and
8.0 kV/mm for samples with moisture content.. The current for the epoxy/E-glass and the
polyurethane/E-glass and basalt samples were also similar. This suggests that for samples with low void
content and relatively high fiber volume, the substitution of basalt fiber for E-glass fiber does not
drastically change the dielectric breakdown properties of the composite material.

Average Breakdown Fields without  Average Breakdown Fields with 
Moisture Content Moisture Content

Epoxy Polyester 1 Epoxy Polyester 1 Polyester 2 Phenolic

Polyester 2 Phenolic 15
15
Field (kV/mm)

10
Field (kV/mm)

10

5
5

0 0
Resin System Resin System

Fig 3. Fig 4.

™ Error bars in the graphs show the standard deviation (S.D) for the tested samples.

Fig. 3. Plot showing the average breakdown fields of 1” samples without any moisture content.
Fig. 4. Plot showing the average breakdown fields of 1” samples with moisture content.
Fig. 5. SEM Micrograph showing void content typical for the phenolic/E-glass pultrusion samples.
Fig. 6. SEM Micrograph showing void content typical for the polyester/E-glass pultrusion samples.

3. Conclusion

The dielectric breakdown voltages of different pultruded composites comprised of different resins with
and without moisture effect have been investigated. Results demonstrated that both the constituent
materials as well as the characteristics of the fabricated part must be considered when describing the
dielectric properties of composite materials. For example, the lower breakdown voltage for the
phenolic/E-glass composites that typically exhibits a higher void content than polyester or epoxy
composites manufactured using similar methods demonstrates the influence of void content on dielectric
breakdown. This analysis demonstrates techniques that can be used to experimentally evaluate the
dielectric breakdown voltages for polymeric composites. Finally, it should be noted that this is an initial
experimental investigation and was pursued because the composites under investigation had already been
manufactured. It is intended by the authors to develop a computer model for the dielectric breakdown
phenomena. The data provided here will give initial data to verify the validity of the computational
model once it has been developed. Once the model is verified, then use of the model will allow design of
composite structures that are able to withstand a certain high voltage without breakdown occurring.

Acknowledgements

The authors would like to thank Tim Hall of the Composite Materials Laboratory, James McPhail of the
ME Machine Shop, and Martye Hickman from the EE department for their valuable help in the research.

References

[1] M. Frohlich, Theory of Dielectrics, Oxford University Press, 1949.

[2] L. Vouyovitch, N.D. Alberola, L. Flandin, A. Beroual and J-L. Bessede, “Dielectric Breakdown
of Epoxy-Based Composites: Relative Influence of Physical and Chemical Ageing” in IEEE
transactions on dielectrics and electrical insulation, 2006, vol. 13, pp. 282-292.
[3] R. Bartnikas, Engineering Dielectrics Volume IIB, Electrical Properties of Solid Insulating
Material: Measurement Techiniques, 1987.
[4] ASTM D 149 – 97a, “Standard Test Method for Dielectric Breakdown Voltage and Dielectric
Strength of Solid Electrical Insulating Materials at Commercial Power Frequencies”.
[5] ASTM D 570 – 95, “Standard Test Method for Water Absorption of Plastics”.
[6] ASTM D 1711 – 83, “Standard Definitions of Terms Relating to Electrical Insulation”.