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Material Spotlight: Teflon® for Electrical Insulation 

ESPE Manufacturing works with a number of electrical insulation materials and with a variety of fabrication methods. Even the most complex specifications are manufactured accurately using techniques such as laser cutting, die cutting, digital plastic cutting, and more. We provide prototyping services and can fabricate custom parts in both high and low production volumes. Our products are available in many suitable materials, including PTFE or Teflon® for electrical insulation purposes.

This blog post will discuss what Teflon® is as well as the many advantages of using Teflon® for electrical insulation products.

What is Teflon®?

Teflon® is the widely recognized brand name for polytetrafluoroethylene (PTFE). PTFE is a type of plastic that is used to coat various products and equipment, creating a non-stick, waterproof, non-reactive, and corrosion-resistant protective barrier. Teflon® is extensively used throughout various industries, including automotive, construction, aerospace, and more, for applications such as pipes, gears, wires, and cables.

Why is Teflon® Good for Electrical Insulation?

Teflon® is impervious to nearly all solvents and chemicals, including those frequently used in electronics manufacturing. It is a very resilient, non-reactive material that can withstand temperatures ranging from -454° F to 600° F (-234° C to 315° C), making it an excellent insulator for electrical applications exposed to extreme heat or cold.

Teflon® is composed of carbon-fluorine bonds that are very flexible, even after significant bending and stressing. Teflon® insulated wires cannot be cross-linked and have a long, reliable flex life. The extreme durability of Teflon® ensures long-lasting protection of electrical components.

Teflon® also displays excellent dielectric strength, making it an excellent electrical insulator. Teflon® coated components are very low friction, meaning components will experience minimal resistance. At ESPE Manufacturing, we can produce a variety of Teflon® electrical insulation products, including:

• Bearings
• Bushings
• Gears
• Slide plates
• Piston rings
• Seals
• O-rings
• Spacers
• And more

Advantages and Benefits of Teflon® Parts

There are many benefits of Teflon® parts, including:

• Versatility. One of the primary benefits of Teflon® parts is their versatility, meaning it is suitable for an extensive range of applications and industries.
• Corrosion resistance. Another key advantage of Teflon® parts is their corrosion resistance, which makes them especially useful for electrical insulation.
• Water and oil resistance. Teflon® parts repel water and oil, which increases the lifetime of the part itself as well as the application it’s used in.
• Non-stick. Teflon® is non-stick, meaning Teflon® parts are easy to clean, typically only requiring a wipe down.
• Low friction. Teflon® parts exhibit low friction properties, which offer reduced wear and longer-lasting components. This makes Teflon® parts an excellent option for industrial applications involving parts or gears that slide against each other.
• Dielectric properties and high melting point. The non-conductive properties and high melting point of Teflon® parts make them a popular choice for electrical wiring and insulation for a variety of industries.

Teflon® Electrical Insulation from ESPE Manufacturing

The significant advantages of Teflon® make it a natural choice for electrical insulation projects. Teflon® parts work longer and more effectively than alternatives and can easily be incorporated into a wide array of applications. ESPE Manufacturing offers a wide range of Teflon® fabrication services that can be customized to meet your application’s exact needs. We have a long history of delivering effective non-metallic solutions, and we possess one of the largest electrical insulation inventories in the Midwest. To learn more, view our catalog or contact us today.

Material Spotlight: Mylar®

Electrical insulation is crucial in various applications to prevent the free flow of electricity. Mylar helps channel electricity where it needs to go while preventing short circuits and eliminating electrocution dangers. ESPE Manufacturing Co., Inc. has an enormous selection of materials to fabricate components and parts that can be used as electrical insulation, including Mylar.

What is Mylar?

In the 1950s, a trio of chemical companies, Hoechst, DuPont, and Imperial Chemical, developed Mylar–a stretched polyester film that is commonly used for solar filters, protective plastic coatings, insulators, space blankets, and shiny helium balloons. The technical composition of the groundbreaking material is biaxially oriented polyethylene terephthalate, or BoPET. NASA was one of the first to use and experience the benefits in its 1964 Echo II balloon.

To create Mylar, molten PET is extruded as a thin film over a chilled roller or other surface. Special machinery draws the film in biaxial directions using heated rollers. The final step involves setting the film by holding it under pressure at a high temperature. The result is an extremely smooth and pure film that adheres to itself. To prevent this, inorganic particles or metals can be embedded in the surface.

The properties of Mylar make it an excellent component for food packaging applications such as yogurt lids, roasting bags, and various foil packages. Because of its electrical insulating properties, it is often used in manufacturing, automotive, electronics, and space travel applications.

Properties

The properties listed below allow for an ideal choice in a wide variety of applications:

• Dielectric strength. Mylar is an excellent electrical insulator with a typical DC dielectric strength of 11.0 kV/mil and a typical AC dielectric strength of 7.0 kV/mil.
• Corona threshold voltage. Mylar has one of the highest corona resistance levels of any plastic film, which makes it able to endure short surges of overvoltages easily.
• Dielectric constant. The typical dielectric constant ranges from 2.8 to 3.7, depending on the temperature of the film.
• Dissipation factor. The typical dissipation factor of Mylar ranges from 0.0002 to 0.016, depending on the temperature of the film.
• Insulation Resistance. Mylar film has exceptional insulation resistance over a broad range of temperatures.
• Volume Resistivity. The volume resistivity of the material decreases as temperature increases, with Mylar Type C having about one order of magnitude higher volume resistivity than Type EL film at 257° F.
• Tracking Resistance. When dry, the material doesn’t track, but moisture can lead to tracking erosion.
• Arc Resistance. Mylar possesses an arc resistance time of 73 to 94 seconds. This shows that the material has an advantage over materials that track.

The Advantages of Mylar for Electrical Insulation

The benefits of Mylar film come from its excellent electrical insulation properties under a wide variety of conditions. In addition to those listed above, it also includes the following advantages for electrical insulation:

Tensile strength and toughness

Mylar is tough and has a higher tensile strength than most insulating materials. It has a tensile strength of 25,000 psi and elongation at 170% without breaking.

Creep

Creep measurements indicate how a material deforms under a wide range of mechanical stressors. Under various conditions, the material resists creep very well.

Thermal aging

UL thermal aging standards show that Mylar has a temperature index of 302° F. This means that it will not degrade at service temperatures below 302° F, providing a long service life for various electrical insulator applications.

Mylar Available from ESPE Manufacturing

Mylar is one of many electrical insulation materials, and it provides a particularly wide range of benefits for industries such as automotive, electrical, lighting, wind energy, and many others. At ESPE, we offer a wide range of electrical insulation materials to fit the specifications of your project. For more information about this material, or to get started on your electrical insulation solution, contact us or request a quote today.