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Formex for Insulation of Batteries & Printed Circuit Boards (PCBs)

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Electrical insulation involves non-electrically conductive material used to control the flow of electricity and protect sensitive components. Various materials can be used, such as rubber, plastic or material like Formex for insulation. These materials work by blocking the passage of electrons more effectively than semiconducting and conducting materials. This means that they can be used as a protective barrier around the conductor, ensuring energy stays on a specific path and doesn’t interact with other components, causing short-circuiting.

Importance of PCB & Battery Insulation

In applications involving PCBs, insulation acts as the dielectric material used to separate conducting elements and layers. Most PCBs used today are multilayered, which means multiple adhesion points are present. This increased board height requires more soldering and makes proper insulation vital to the board’s effectiveness. In PCB applications, having a thorough understanding of your PCB’s construction is the best way to ensure it’s insulated adequately and can operate at its highest potential.

Another key application for electrical insulation is in batteries. Electrical vehicle batteries, for example, require insulation between each component to ensure no electrical arc can arise between battery components. This is a necessary precaution to prevent fires, shocks, high temperatures, short circuits, and more.

When choosing a material to insulate PCBs and batteries, there are several factors that should be considered. One of the primary concerns is the material’s thickness in relation to its efficiency. Insulating material needs to be highly effective, but thickness also needs to be taken into account. Certain insulation applications feature highly compact components that are not suited to a particularly thick material.

It’s also important to consider what type of processing your insulator should undergo. Certain insulation materials are significantly easier to process than others and, depending on your application, this may be a significant concern. However, an easy-to-process material might not perform according to your required standards. Insulation weight and cost-to-function ratio should also be factored into decision-making. For PCB and battery insulation applications, a particularly high-performing material is ITW Formex. This material is uniquely suited to PCB and battery applications, meeting all of the typical demands.

Why Formex?

ITW Formex is ideal for protecting delicate components and is widely used throughout many applications. It offers excellent dielectric strength and provides reliable mechanical protection. Formex can be formed into even the most complex three-dimensional shapes by die-cutting, scoring, and bending. In PCB insulation applications, Formex is used for barriers between PC boards as well as between PC boards and housings.

Formex electrical insulation is made from polypropylene, which is lightweight and inexpensive, while meeting rigorous electrical barrier and insulation requirements. With a flame class rating of UL 94V-0, Formex has excellent flame-retardant properties and will not combust or melt at temperatures up to 239° F.

Additionally, ITW Formex features several key characteristics that allow it to outperform other insulation materials, such as preventing electrically charged components from arcing. Formex is ideal for many types of EV battery applications as it protects from contact corrosion, provides EMI shielding capabilities, and more. For electric vehicle battery applications, Formex stands up to chemical, mechanical, and environmental demands.

ESPE Manufacturing: Your Source for Reliable Insulation

PCBs and batteries are used throughout nearly every industry and require high performing, reliable insulation. Formex contains many beneficial characteristics that make it ideally suited to these applications. In addition to being uniquely easy to shape, it also features notable strength and valuable fire-retardant properties, all while being cost-effective.

ESPE Manufacturing Co., Inc., has been providing high-quality electrical insulation solutions since 1948 and features one of the largest inventories in the Midwest. We offer ITW Formex rolls and sheets and carry several varieties suitable for a wide selection of applications. Our experts can help you select the best type for your project. Browse our catalog or contact us to get started. To partner with us and take advantage of Formex insulation for your application, request a quote today.