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CNC Machined PEEK Insulator Block with High Dielectric Strength and Creepage Distance Control for High-Voltage Systems

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Mrs. Yang

kristen.yang@jinbo-china.com

+86 13798898651

Y13798898651

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CNC Machined PEEK Insulator Block with High Dielectric Strength and Creepage Distance Control for High-Voltage Systems

विस्तृत जानकारी

उत्पाद का वर्णन

विस्तृत जानकारी

सामग्री विकल्प:

PEEK 450G (बिना भरा हुआ), PEEK 450CA30 (30% CF), PEEK 450FE20 (20% PTFE चिकनाई युक्त)

सहनशीलता:

+/- 0.03 मिमी (बोर), +/- 0.05 मिमी (सामान्य), +/- 0.02 मिमी (क्रीपेज सतह)

सतही समापन:

रा 0.8 (बोर सतह), रा 1.6 (सामान्य), रा 3.2 (गैर-महत्वपूर्ण)

ढांकता हुआ ताकत:

20 केवी/मिमी (अनफिल्ड पीईके)

अधिकतम ब्लॉक आकार:

300mm X 200mm X 100mm

परिचालन तापमान:

-60C से +250C (निरंतर)

उत्पाद का वर्णन

CNC Machined PEEK Insulator Block for High-Voltage Electrical Systems

PEEK (polyetheretherketone) is one of the few engineering plastics that can serve as both a structural component and an electrical insulator at 150°C+ operating temperatures. Its dielectric strength is around 20 kV/mm, meaning a 5mm wall thickness can hold back 100,000 volts—but only if the wall is dimensionally consistent and free of cracks, voids, or stress concentrations from poor machining.

We machine PEEK insulator blocks on CNC milling centers with specific process parameters optimized for this material. The spindle speed is higher (8,000-12,000 RPM), the feed rate is lower to prevent melting, and we use compressed air instead of flood coolant. Critical features include bore holes, mounting hole positions, and creepage distances between conductive paths, all maintained to ensure IEC 60664 compliance.

Key Features

Victrex PEEK 450G or Equivalent: Grade-specific PEEK with full material traceability and material test reports
Creepage Distance Control: Slots and barriers machined to ±0.05mm positional accuracy with Ra 1.6 or better surface finish
Thermal Stability: Maintains mechanical and dielectric properties up to 250°C
Stress-Free Machining: Low depth of cut, high spindle speed, air blast cooling with post-machining annealing
High Dielectric Strength: 20 kV/mm dielectric strength with CTI 175V minimum for unfilled PEEK

Technical Specifications

Specification	Details
Product Name	CNC Machined PEEK Insulator Block
Material Options	PEEK 450G (unfilled), PEEK 450CA30 (30% CF), PEEK 450FE20 (20% PTFE lubricated)
Tolerance	±0.03mm (bores), ±0.05mm (general), ±0.02mm (creepage surfaces)
Surface Finish	Ra 0.8 (bore surfaces), Ra 1.6 (general), Ra 3.2 (non-critical)
Dielectric Strength	20 kV/mm (unfilled PEEK)
Max Block Size	300mm × 200mm × 100mm
Operating Temperature	-60°C to +250°C (continuous)
Certifications	ISO 9001:2015, RoHS, CE, UL 94 V-0 (flammability)
Lead Time - Prototype	5-7 days
Lead Time - Production	7-15 days
MOQ	10 pieces (prototype), 50+ (production)
Origin	Dongguan, China

Applications

Switchgear Insulators: Barrier and support insulators for medium-voltage switchgear (3.6kV to 36kV)
EV Inverter Insulation: Insulator blocks between IGBT modules and heatsinks in EV power inverters
Busbar Support Blocks: Insulating support blocks for high-current busbar systems in power distribution equipment
Transformer Terminal Boards: Insulating terminal boards for dry-type transformers with controlled creepage distances
Fuse Holder Insulators: Insulator housings for high-voltage fuse assemblies
Test Equipment Insulation: Insulator components for high-voltage test equipment and dielectric withstand test fixtures

Why Choose Sinbo Precision

PEEK Machining Process Control: Optimized parameters developed over years of production experience
Creepage Distance Expertise: Comprehensive understanding of IEC 60664 requirements
Material Traceability: Every block traceable to material lot with test reports available
Stress Relief Annealing: Standard annealing cycle (2 hours at 150°C) for dimensional stability
Inspection for Insulation: 10x magnification inspection for micro-cracks and surface defects
Design Support: Complete design services based on electrical requirements and operating conditions

Manufacturing Process

Design Review: Analysis of electrical requirements, material selection, and mechanical load requirements
Material Preparation: Certified PEEK stock with verified material test reports
CNC Milling: Roughing and finishing with optimized parameters and compressed air cooling
Annealing: Post-machining stress relief at 150°C for 2 hours with controlled cooling
Secondary Operations: Tapping threads and deburring all edges
Inspection: CMM verification, visual inspection, surface finish measurement, and optional hi-pot testing

Frequently Asked Questions

Unfilled PEEK or carbon-filled PEEK for my insulator?

Unfilled PEEK (450G) for 95% of insulator applications. It has the highest dielectric strength and best tracking resistance. Carbon fiber filled PEEK (450CA30) is mechanically stronger but reduces dielectric strength by about 30%. Use CF-PEEK only when the insulator serves as a structural load-bearing component.

Can PEEK replace ceramic insulators?

Yes, in many medium-voltage applications. PEEK has better impact resistance, thermal shock resistance, and can be machined into complex shapes. The limitation is surface tracking—for polluted environments, you may need longer creepage distances in PEEK than in ceramic.

Why anneal PEEK after machining?

Machining introduces residual stress that can cause warping at elevated operating temperatures. Annealing relieves these stresses in a controlled manner, ensuring dimensional stability and maintaining proper creepage distances during service.

What's the maximum voltage rating for a PEEK insulator block?

The voltage rating depends on design factors including creepage distances, wall thickness, and pollution degree. Medium-voltage switchgear up to 36kV class commonly uses PEEK insulators. For high-voltage applications (>36kV), ceramic or composite insulators are typically preferred.

Can you machine PEEK insulators with metal inserts?

Yes. We can install threaded brass or stainless steel inserts (heat-set or ultrasonically installed) with controlled processes to avoid cracking the PEEK. Insert pull-out strength is tested on a sample basis.

What's the lead time for 50 insulator blocks?

7-10 days for unfilled PEEK (450G) with no inserts. Add 3-5 days for inserts, 5-7 days for carbon-filled PEEK. Material availability may affect lead times for specialty grades.

टैग:

Sinbo Precision Mechanical Co., Ltd.

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सीएनसी स्टेनलेस स्टील भागों

सीएनसी पीतल के पुर्जे

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सीएनसी विनिर्माण समाधान

CNC Machined PEEK Insulator Block with High Dielectric Strength and Creepage Distance Control for High-Voltage Systems