High-Voltage Polymer Insulation

High-voltage polymer insulation — creepage and clearance, tracking resistance, material selection, and design for 400V/800V architectures.

Private cohorts & on-site
Format: 2-day (8:30 a.m.–4:30 p.m.)
Level: Advanced
Location: Scheduled on demand · on-site at your facility or a regional venue
Date(s): Not yet scheduled for open enrollment. Get notified when it is, or book it privately for your team.
Includes: Certificate of Completion · printed slide binder · take-home reference text

Get notified when this course is scheduled

One email when dates are set. Or skip the wait: run it as a private cohort, on-site at your plant.

Talk to us about a private cohort
  • One email, no sequence
  • Never shared
  • Reply within one business day

Faculty

Faculty details for this seminar will be announced with the full schedule.

Fees

Early: $1,895 (payment 4+ weeks ahead)
Standard: $2,095 (check/ACH) · $2,165 (card)

Group discount: $200 off per attendee for 3+ from the same organization.

Also Available

  • Corporate on-site delivery at your facility
  • Private cohort sessions
  • Digital curriculum licensing

Seminar Overview

As vehicles, infrastructure, and industrial systems move to higher voltages, polymer insulation is where dielectric failures occur — and the consequences are catastrophic and litigable. This seminar covers the physics and engineering of polymer insulation for high-voltage applications: dielectric materials, tracking and erosion, partial discharge, temperature effects, and the design/processing levers that prevent premature insulation failure. Taught by an ISO/IEC 17024-certified plastics expert witness, it combines fundamentals with the failure-analysis view.

Ideal Learner

  • Insulation and dielectric engineers at OEMs and suppliers
  • High-voltage component engineers (connectors, cabling, enclosures)
  • Materials engineers selecting insulation polymers
  • Failure-analysis and reliability engineers
  • EV and industrial high-voltage program engineers

Learning Objectives

  • Explain dielectric breakdown mechanisms in polymer insulation
  • Apply tracking, erosion, and partial-discharge theory to design
  • Select polymer systems for voltage class, temperature, and environment
  • Design geometry and processing to manage electrical stress
  • Investigate premature insulation failure in the field

Consulting Sessions

Seminar attendees can sign up for individual consulting sessions with the instructor. Sessions are free for registered attendees, first-come first-served — sign up when registering by calling 248-539-0473 or during the seminar.

Seminar Outline

  • Dielectric strength, permittivity, dissipation factor
  • Breakdown mechanisms: intrinsic, thermal, electromechanical, treeing
  • Temperature and frequency effects on insulation performance
  • Carbonization and tracking across polymer surfaces
  • Dust, moisture, and pollution-induced mechanisms
  • Reported tracking, CTI, and standards (IEC 60112, UL 746A)
  • Partial discharge in voids and interfaces
  • Designing to suppress PD: geometry, molding quality, material choice
  • PD testing and interpretation
  • EPDM, silicone, XLPE, PET, FR-PA, and specialty systems
  • Filler and additive effects on dielectric performance
  • Trade-offs: dielectric vs. mechanical vs. thermal
  • Creep distance, radii, and stress-relief geometry
  • Molding quality: voids, weld lines, and contamination as weak points
  • Aging and environmental effects on long-term insulation
  • Case studies of H/V insulation failures
  • Evidence-based root-cause methodology
  • Attendee failure review and prevention plan

More in Track E — EV, ADAS & Software-Defined Vehicle

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