Insulating films, adhesive tapes and die-cut parts for EMS manufacturers

The example of a Kapton® film clarifies the above statement:

If you want to build a particularly compact electrical/electronic device, you come up against various limits. The smaller the device, the higher the energy density. In the simplest case, this means a higher temperature load. Within certain limits, components with a corresponding temperature class can be selected.

For insulation films, this means, for example: If the temperature load regularly or permanently exceeds the limit of 130°C, the very good and inexpensive polyester film can no longer be used as insulation film. Its upper limit is 130°C (class B) and its service life at this operating temperature is just 2.5 years. At this point, the dielectric strength has dropped by 50% due to ageing alone. Adhesive tapes made from Kapton® films, on the other hand, are designed for up to 180°C and have a very long service life.

However, a compact design is not only achieved by increasing the energy density and using higher temperature-resistant components. This is an "expensive" process. It is better to dissipate the heat effectively so that the temperature does not rise in the first place. In electronics production , this is achieved primarily by thermally conductive products such as thermal pads, thermal paste or very thin, thermally conductive insulation foils made of Kapton® MT.

Polyester films would be counterproductive in this case, as they have a much higher thermal resistance and therefore tend to hinder heat dissipation.

EMS service providers naturally know of other ways to increase the structural density. However, the standardized clearance and creepage distances must be observed. These become smaller (more compact) the cleaner the environment is (pollution class) and the higher the temperature class is. Above all, however, the sensitivity to creepage path formation must be low (cti value, comparative tracking index). Polyester film has a clear advantage in this respect (cti=1 instead of cti=4 for Kapton®) and allows shorter tracking paths.

Conclusion: not every plastic film is equally suitable for every electrotechnical application.

Especially when using conventional components (THT), insulation stampings between the component and multilayer boards (PCB, FPC, RPC) can make a contribution. They help to save space and still ensure reliable insulation. In addition to the electrical function, heat loss can also be dissipated by equipping the insulation die-cut parts with heat conductors.

EMS producers have experience in the conception, design and production of printed circuit boards, electronic components and devices for their customers. CMC Klebetechnik, on the other hand, offers extensive expertise in technical films and coatings. They can help to make electronic assemblies more compact, reliable and durable. They can also make assembly considerably cheaper (die cutted parts made of insulating films) or simplify assembly production because creepage distances are created differently and air gaps are reduced - from prototypes to PCBs ready for series production.

Of course, the above also applies to companies that carry out other work on a contract basis (contract manufacturing). For example, switch cabinet construction for process technology, conveyor technology, turbine technology, the chemical industry or mechanical engineering, where die-cutted parts made of rigid, stable polyester or polycarbonate film ensure reliable insulation between 19" rack inserts.

There is an almost unlimited number of applications for adhesive tapes in industrial electronics, drive technology, pump control, medical technology, aviation, security technology and white goods, communication electronics and electrical engineering in general - ask us if you feel that a film (adhesive tape, die-cut part) could be the solution for your task. For insulation, fastening, heat dissipation or electromagnetic shielding.