The History and Future Five-Year Development Opportunities of APG Process in the Electrical Insulation Field

1. Introduction​

The Automatic Pressure Gelation (APG) process has emerged as a crucial technology in the electrical insulation field, significantly influencing the production of high-quality epoxy-resin-based insulation products. Understanding its history provides insights into its evolution, while exploring future development opportunities helps stakeholders anticipate market trends and technological advancements.​

2. History of APG Process​

• 2.1 Early Development​

The APG process was first successfully developed by the Swiss company CIBA-Geigy in 1969. This innovation was a response to the growing need for more efficient and high-quality manufacturing processes in the electrical industry. At that time, the development of epoxy resins, curing agents, and auxiliaries in materials science had reached a certain level, enabling the realization of the theory of rapid-process technology for epoxy resins. Before the advent of APG, epoxy resin products in the electrical insulation field were mainly produced through traditional methods such as vacuum casting, which had limitations in terms of production efficiency and product quality consistency.​

• 2.2 Industrial Application and Expansion​

In 1975, the APG process began to be put into industrial production. It quickly gained popularity in the international market due to its remarkable advantages. The process was characterized by a short production cycle, high product precision, and a high mold utilization rate. For example, compared with traditional casting methods, the production time of a single batch of electrical insulation products using the APG process could be reduced by 30% - 50%, and the dimensional accuracy of products could be controlled within a much smaller tolerance range.​

In the late 1980s, China introduced the APG technology, including a complete set of equipment, formulas, and supporting chemical materials. This introduction significantly improved the quality of epoxy resin integral insulation structures in China's electrical industry. Since then, Chinese researchers have made continuous efforts to localize the APG technology. After nearly a decade of research, they achieved a breakthrough in the localization of hydraulic pressure equipment and supporting epoxy resin materials for the APG technology, replacing imported equipment and materials. By the present day, domestic APG technology has reached a high level of maturity, and the domestic production of APG-related equipment and materials has met a large part of the domestic market demand.​

3. Future Five-Year Development Opportunities​

• 3.1 Growth in the Electrical Insulation Market​

The electrical insulation market is expected to experience substantial growth in the next five years, which will directly drive the demand for the APG process. In the power generation sector, the continuous expansion of renewable energy sources such as wind power and solar power requires a large number of high-performance electrical insulation products. For instance, in wind turbines, the insulation of generators and transformers is crucial for ensuring stable operation. The APG process, with its ability to produce high-quality insulation components with excellent electrical and mechanical properties, is well-suited for manufacturing these components.​

In the power grid construction and transformation, the upgrading of the power grid to a smart grid and the construction of ultra - high - voltage transmission lines also increase the demand for reliable electrical insulation. The APG-produced insulation products can better withstand high-voltage and complex environmental conditions, thus being highly favored in the power grid market.​

• 3.2 Technological Advancements​
• 3.2.1 Material Innovation​

In the coming five years, there will be continuous innovation in epoxy resin materials used in the APG process. Researchers are expected to develop epoxy resin mixtures with lower viscosity, longer pot life, faster curing speed, and better electrical and mechanical properties. For example, new types of epoxy resins with enhanced heat resistance may be developed, which can further improve the performance of electrical insulation products under high - temperature operating conditions. This material innovation will not only expand the application scope of the APG process but also improve the competitiveness of products produced by this process.​

• 3.2.2 Process Optimization​

The APG process itself will also be optimized. The introduction of advanced control systems and sensors will enable real-time monitoring and precise regulation of process parameters such as temperature, pressure, and filling speed. This will lead to more stable product quality and higher production efficiency. For example, through the use of intelligent control technology, the defect rate of products can be reduced by 10% - 20%, and the production efficiency can be increased by 20% - 30%.​

• 3.3 Environmental and Regulatory Factors​

With the increasing global emphasis on environmental protection and sustainable development, the APG process has significant advantages. The APG process is a closed-loop system with no solvent pollution and energy-saving features, which is in line with strict environmental regulations. In the next five years, as environmental regulations become more stringent, especially in developed countries and regions, the demand for environmentally friendly manufacturing processes like APG will continue to grow.​

Moreover, the "dual-carbon" goal proposed by many countries also promotes the development of the APG process. The APG-produced electrical insulation products can contribute to the energy-saving operation of electrical equipment, helping the electrical industry reduce its carbon footprint and meet the requirements of the "dual-carbon" target.​

• 3.4 Market Expansion in Emerging Economies​

Emerging economies in Asia, Africa, and South America are in a stage of rapid industrialization and urbanization. The construction of infrastructure such as power plants, power grids, and industrial facilities in these regions will generate a huge demand for electrical insulation products. In the next five years, these emerging economies are expected to become important growth engines for the APG process market. For example, countries in Southeast Asia are planning large - scale power grid construction projects, which will create a vast market for APG-produced insulation components.​

• 3.5 Synergy with Related Industries​

The APG process is also likely to benefit from the synergy with related industries. For example, in the development of electric vehicles, the demand for high-performance electrical insulation in batteries, motors, and charging systems is increasing. The APG process can collaborate with the electric vehicle industry to develop specialized insulation products that meet the unique requirements of electric vehicles, such as high-voltage resistance, vibration resistance, and thermal stability. This cross-industry synergy will open up new application scenarios for the APG process and expand its market share.​

4. Conclusion​

The APG process has a rich history of development, from its initial invention to widespread industrial application and continuous improvement. Looking ahead to the next five years, the APG process in the electrical insulation field is faced with numerous development opportunities. The growth of the electrical insulation market, technological advancements, favorable environmental and regulatory factors, market expansion in emerging economies, and synergy with related industries will all contribute to its further development. Manufacturers and investors in the APG process should seize these opportunities, increase R&D investment, and promote technological innovation to gain a competitive edge in the future market.