Phenolic & Thermoset Electrical Moulding Compounds — Manufacturer in India
ACC Insulations manufactures high-performance phenolic and composite thermoset moulding compounds Components for demanding electrical insulation and structural applications. Each compound delivers consistent dielectric strength, arc resistance, and thermal durability across switchgear, transformer, motor, and automotive environments.
Suitable for compression moulding, transfer moulding, and injection moulding processes. Grades available in novolac and resol resin systems. Custom formulations supplied on request.
Key Electrical & Mechanical Properties
Resists electrical breakdown under high voltage loads.
Stable performance under prolonged thermal cycling.
CTI >600V grades available for high-voltage assemblies.
Low creep. Tight tolerances maintained after moulding.
Retains insulation properties in humid environments.
Self-extinguishing grades per IEC standards.
Product Specifications
| Moulding Compound — Technical Data | |
|---|---|
| Resin System | Phenolic Novolac, Phenolic Resol (non-ammonia), Composite |
| Available Grades | PFCC01, PFCC04, F2, F3, F4, PFCP02, PFCP03, P2, P3 |
| Sheet Thickness | 0.5 to 100 mm |
| Sheet Sizes | 1220 × 2440 mm | 1220 × 1220 mm |
| Max. Operating Temp. | Up to 200°C (grade-dependent) |
| Moulding Processes | Compression, Transfer, Injection |
| Compliance | IEC, IS standards |
| Custom Grades | Available on request |
Grade Selection Guide
Match grade to thermal class, filler type, and application requirement.
| Grade | Resin Base | Key Strength | Primary Use |
|---|---|---|---|
| PFCC01 | Phenolic Resol | High CTI, Low corrosion | Terminal blocks, circuit breakers |
| PFCC04 | Phenolic Resol | Dimensional precision | Precision switchgear components |
| PFCP02 | Phenolic Novolac | Fast cure, heat resistance | Transformer insulation parts |
| PFCP03 | Phenolic Novolac | Chemical resistance | Industrial machinery components |
| F2 / F3 / F4 | Composite | Mechanical strength + flame retard. | Motor components, automotive |
| P2 / P3 | Phenolic | General insulation, economy grade | Mass-produced electrical parts |
Manufacturing Process
Controlled resin formulation ensures batch-to-batch consistency for critical insulation applications.
Phenolic or composite resin blended with hardener at precise stoichiometry for target thermal class.
Glass fibre, mineral, or organic filler dispersed uniformly — controls mechanical strength and dielectric properties.
Resin-filler matrix mixed, calendered, and granulated into consistent flow-grade pellets or powder.
Controlled curing cycle. Each batch tested for dielectric strength, arc resistance, and dimensional tolerances per IEC/IS norms.
Industry Applications
Technical Advantages over Conventional Insulators
- Uniform properties across complex 3D moulded shapes — not achievable with laminates.
- Novolac resin grades resist temperatures up to 200°C — superior to standard thermoplastics.
- CTI >600V tracking resistance for high-voltage switchgear safety.
- Low creep under mechanical load — maintains precision tolerances over service life.
- Low moisture absorption retains dielectric strength in humid, tropical climates.
- Flame-retardant formulations self-extinguish — meet UL 94 V-0 equivalent standards.
- Cost-effective for mass production — compression and injection moulding compatible.
- Non-ammonia resol grades eliminate metal corrosion in precision components.
How to Select the Right Grade
Four parameters drive grade selection:
Contact our technical team for application-specific grade recommendations and datasheets.
Why Choose ACC Insulations
- Dedicated phenolic & thermoset compound Components fabricating in India.
- 9 standard grades — plus custom formulations for OEM applications.
- Strict batch testing: dielectric strength, arc resistance, dimensional inspection per IEC/IS.
- Experience supplying switchgear, transformer, and motor OEMs across India.
- Bulk supply capability for mass production schedules.
- Technical support for grade selection, moulding trials, and specification matching.
Frequently Asked Questions
What grades of electrical moulding compounds does ACC Insulations supply?
PFCC01, PFCC04, PFCP02, PFCP03, F2, F3, F4, P2, P3. Custom formulations available on technical request.
Maximum operating temperature for phenolic moulding compounds?
Standard grades handle 130–180°C continuous. Novolac heat-resistant grades rated to 200°C.
Difference between phenolic novolac and resol grades?
Novolac: faster cure, superior heat and chemical resistance. Resol (non-ammonia): extremely low metal corrosion, better electrical properties for precision contacts.
Moulding processes compatible with these compounds?
Compression, transfer, and injection moulding — supporting both low-volume prototypes and high-volume mass production.
Do you supply custom sheet sizes?
Standard sizes: 1220 × 2440 mm and 1220 × 1220 mm. Custom cut-to-size available on request.
Insulation Grade Calculator
Match moulding compound grade to IEC/IS dielectric safety margins. Enter voltage class, operating temperature, and environment — get grade recommendation instantly.
