Electrical & Boxes

Gilsonite for Electrical & Boxes

Zagros Gilsonite supplies high-quality Gilsonite for electrical insulation, battery boxes, cable coatings, and electrical component encapsulation. As a direct mine owner, we deliver consistent, high-performance natural asphaltite with high dielectric strength, excellent thermal stability, and superior acid and water resistance.

Whether you manufacture storage battery cases, insulate cables and wires, pot transformers and coils, or produce electrical insulation boards, our Gilsonite helps improve product performance, reduce raw material costs, and simplify formulation.

 

Why Use Gilsonite in Electrical & Box Applications?

Gilsonite is a natural, carbonaceous hydrocarbon resin with near-perfect insulator qualities. Its low melting point, high solubility in oils, and excellent dielectric properties have made it a valuable material in electrical applications since the late 1800s, when Samuel H. Gilson first marketed it as an electrical insulator and waterproofing compound.

Key benefits:

· High dielectric strength and electrical resistivity (4.0 x 10¹² ohm-cm)
· Excellent thermal stability and heat resistance
· Superior water and moisture impermeability
· Outstanding acid and chemical resistance
· Good adhesion to metals, fibers, and fillers
· Compatible with rubbers, asphalts, and synthetic polymers
· Cost-effective compared to many synthetic insulating resins
· Consistent quality from a direct mine source

Key Applications

 

1. Battery Boxes & Storage Battery Cases

Gilsonite has been used in battery boxes since 1904, making it one of the most established applications for this versatile material. As a key component in asphaltic battery case compositions, Gilsonite provides the ideal balance of hardness, toughness, and resistance to acid and temperature distortion.

Best for:

· Lead-acid storage battery cases
· Industrial and automotive battery boxes
· Battery container compositions
· Acid-resistant battery housings

Benefits:

· Excellent acid resistance against battery electrolytes
· High hardness with good toughness and shatter resistance
· Resistance to distortion at elevated temperatures
· Waterproof and chemically inert
· Can be blended with blown asphalts, mineral fillers, and fibrous reinforcements
· Proven performance in demanding battery environments

Typical composition: 17% select Gilsonite, 28% volcanic pumice stone, and 22% acid-proof asbestos, with the balance being petroleum asphalt and fibrous binders.

 

2. Electrical Insulation & Cable Coatings

Gilsonite is used as an insulating material in electrical cables and wires due to its high dielectric strength and thermal stability. It was first marketed as an electrical insulator and waterproofing compound in the 1880s, and remains a valued material for cable and wire insulation today.

Best for:

· Wire and cable insulation
· Submarine cable compounds
· Communication cable insulation
· Underground pipe insulating jackets
· Electrical insulation boards
· Waterproofing for electrical components

Benefits:

· High dielectric strength (1150 volts/mil short time)
· Improved dielectric stability on exposure to water
· Reduced changes in electrical properties under wet conditions
· Excellent thermal stability
· Superior water and moisture resistance
· Good flexibility and durability

Research has shown that Gilsonite in Buna S compounds improves dielectric stability on exposure to water over extended periods, making it suitable for submarine cable insulation and other demanding applications.

 

3. Potting Compounds & Coil Impregnants

Gilsonite is a proven base material for potting compounds and coil impregnants used in inductive electrical devices, including transformers, inductors, ballasts, and coils. Modified Gilsonite-based encapsulating systems offer excellent sound suppression, thermal conductivity, and dielectric stability.

Best for:

· Transformer potting compounds
· Inductor and coil encapsulation
· Ballast potting for fluorescent lighting
· Coil impregnation for electrical devices
· Electrical component encapsulation

Benefits:

· Superior sound suppression (5.55 db improvement over blown asphalt)
· Excellent thermal conductivity for heat dissipation
· High dielectric stability
· Good rheological properties for complete encapsulation
· Water imperviousness
· Ease of repair by scraping and digging
· Cost-effective compared to alternative potting materials

Gilsonite-based potting compounds and coil impregnants have demonstrated significant sound reduction compared to traditional blown asphalt compositions, with almost a fourfold decrease in sound power.

 

4. Electrical Insulation Boards & Moulded Parts

Gilsonite is used in electrical insulation boards and moulded electrical parts where its insulating properties, dimensional stability, and resistance to moisture and chemicals are essential.

Best for:

· Electrical insulation boards
· Moulded electrical components
· Insulating spacers and separators
· Switchgear and panel components
· Specialty electrical housings

Benefits:

· High electrical resistivity
· Good mechanical strength
· Excellent moisture resistance
· Thermal stability
· Dimensional stability
· Cost-effective moulding material