Temperature, Chemical Resistance, and Fire Retardancy
Energy is one of the top priorities in today's world and the need for energy is constantly growing. This creates new challenges for grids and energy supply infrastructure where high temperatures, chemical resistance and fire retardancy become increasingly important. Various materials and solutions exist to ensure the safety and performance of electrical applications. However, not all electrical insulation materials are created equal.
Let us have a deeper look at high-temperature, chemical-resistant, and fire-retardant electrical insulation materials and the advantages special adhesive tapes and films provide. This shall help to provide guidance on how to choose the right tape solution for your application.
Electric mobility, fast charging, the switch to power industries and production with electric energy are only a few examples where lots of energy is needed in a short time. Dealing with high voltage and currents can cause enormous stress for electro-mechanical components, such as heat and high temperatures.
Motors, transformers, and generators, where high levels of heat are generated, require materials that can withstand these extreme conditions. Without proper insulation, electrical components can fail, leading to costly repairs and potential safety hazards. This is where special insulation tapes with high temperature resistance can make the difference.
But there are some key considerations to keep in mind when selecting materials for high-temperature applications. Due to their unique chemical structures, acrylic, rubber, and silicone adhesives exhibit distinct thermal properties. While all three adhesive types can be modified with different technologies and additives, silicone adhesives typically provide the highest temperature resistance.
Like with adhesives, different backing materials like polyimide (including Kapton®), fluoropolymers (e.g. PTFE, FEP, ETFE), aluminum foil or glass cloth have specific properties which should be considered in selecting the right solution for the application needs. Thermal classes for adhesive tapes are a good first step to narrow down the options but there is more to consider. As thermal resistance is typically not the only requirement of a tape, let us look at chemical resistance and fire retardancy first before we continue with a general tape selection guide.
Electro-mechanical applications often involve exposure to chemicals, solvents, oils, and other fluids that can cause stress, corrosion, wear and damage to parts and components. Therefore, tapes and films are important to protect components exposed to such substances, from degradation, loss of their mechanical properties, or weakening and to avoid potential safety hazards and costly repairs.
It is important to select electrical insulation materials that can withstand exposure to the specific chemicals and substances of the application to maintain their integrity and protect the components. Typically, acrylic and silicone adhesives combined with polyester, polyimide or fluoropolymer backings provide the highest chemical resistance grades. Depending on the specific application needs, an ideal combination can reduce the risk of failure and significantly extend the lifetime which can reduce downtime and improve productivity.
The combination of heat and chemical substances in electro-mechanical applications should not be underestimated, because it can lead to serious consequences: fire.
No doubt, fire retardancy is highly important to avoid damage to electrical components and safety hazards to personnel. Electrical components that are not properly protected from fire can release toxic gases and smoke, cause explosions, and lead to costly repairs or replacements.
To improve fire retardancy in electro-mechanical applications, it is crucial to select electrical insulation materials that can prevent or delay the spread of fire, such as specialized tapes that add an additional layer of protection. These tapes are typically made with materials that can withstand high temperatures and prevent the spread of flames. Common backing materials for fire retardant tapes include polyimide, glass cloth, and ceramic fiber, while silicone rubber is a common adhesive material.
Additionally, tapes can be used to cover and insulate electrical components, preventing the spread of fire and protecting them from heat damage.
With so many options for adhesives and backings, it is not easy to identify the right solution for the specific applications. The following overview is intended to serve as an aid and at least provide initial clues to quickly find potential solutions.
The decisive factor in the search for the right adhesive tape are always the specific requirements of the respective application. It specifies which minimum requirements must be met, but also which solutions are potentially overengineered.
For high-end applications with tough or even extreme temperature environments, silicone adhesives combined with polyimide backing materials are the preferred choice. Silicone adhesives exceed others in withstanding high temperatures without losing their adhesive properties. As backings, polyimides can withstand higher temperatures of up to up to 400–500°C while still maintaining their dimensional stability and mechanical properties. This adhesive and backing combination offers the highest fire protection performance. Polyimides also have excellent electrical insulation properties and are highly resistant to chemicals and radiation, which makes them suitable for use in harsh environments.
Fluoropolymers, on the other hand, can be the ideal choice where slightly lower temperature resistance is acceptable. Their excellent non-stick properties and superb resistance to chemicals as well as strong dielectric properties make them the preferred choice for use in applications where strong chemical resistance or low friction is required.
No wonder that the highest performing combination of polyimides or fluoropolymers with silicone adhesives is also at the top of the price pyramid. Acrylic adhesives combined with polyester backings perform well in a broad temperature range and provide reliable chemical resistance and offer good cost performance ratio.
For medium heat and fire resistance requirements, glass cloth tapes with rubber adhesives might be the ideal choice due to their good material properties.
Although we now have an overview that allows a very first preference, it is crucial to discuss the exact application requirements with your tape expert to identify the solution that fits best. Our experts not only know the existing portfolio consisting of a multitude of options by heart, but they also know how to customize a tape to your specific requirements if needed. Unleash the full power of your application with your tape experts to electrify the world.