Mylar Films/Electrical Insulation Materials: Complete Guide to Properties, Selection, and High-End Applications

Mylar Films/Electrical Insulation Materials:

1. Material Overview: What Are Mylar Films?

Mylar films (polyester films) are high-performance electrical insulation materials widely used in electronics, electrical systems, and industrial applications due to their exceptional dielectric strength, mechanical properties, and temperature stability. Key variants include:

• PET Mylar Films (Polyethylene Terephthalate): Cost-effective general-purpose insulation.
• PI Mylar Films (Polyimide, e.g., Kapton®): High-temperature resistance up to 250°C for extreme environments.
• Composite Mylar Films: Reinforced with fibers or foils (e.g., DuPont™ Nomex®) for enhanced mechanical strength.

2. Key Performance Parameters (Why Choose Mylar Films?)

1. Electrical Properties
   • Dielectric Strength: ≥150 kV/mm (up to 300 kV/mm for PI films).
   • Surface Resistance: 10¹⁴–10¹⁶ Ω (prevents leakage and arcing).
   • Dielectric Constant: 3.0–3.5 (at 1 kHz).
2. Mechanical & Physical Properties
   • Tensile Strength: 150–250 MPa (up to 400 MPa for PI films).
   • Temperature Range: -269°C to +250°C (PI films).
   • Thickness Range: 0.025mm–0.5mm (suitable for precision die-cutting).
3. Environmental Resistance
   • Chemical Resistance: Withstands oils, solvents, and acids (PI films excel).
   • Flame Retardancy: UL 94 V-0 rated (most PI and composite films).
   • Humidity Stability: Water absorption <0.8% (0.2% for PI films).

3. Selection Guide: How to Choose the Right Insulation Film?

Application Scenario	Recommended Material	Key Advantages
Motor Slot Insulation	PET Mylar Films	Cost-effective, high dielectric strength
Flexible Printed Circuits (FPC)	PI Mylar Films	Solder-temperature resistance, dimensional stability
EV Battery Insulation	Nomex® Composite Films	Flame retardant, high-temperature resistant, mechanically robust
Transformer Layer Isolation	Polyimide Films	Corona resistance, long lifespan

4. High-End Application Cases

1. Aerospace
   PI films are used in satellite cable insulation, enduring extreme temperature fluctuations and radiation.
2. Medical Devices
   ISO 10993-compliant medical-grade Mylar films for MRI equipment insulation and surgical instrument packaging.
3. New Energy Sector
   PET-based insulation for photovoltaic backsheets and PI/Nomex® films for EV battery module isolation.

5. Customization and Processing Services

We offer:

Certification Support: Full compliance with UL, RoHS, REACH, and ISO 9001 standards.

Precision Die-Cutting: ±0.1mm tolerance for complex shapes (e.g., perforated, multi-edge designs).

Composite Processing: Lamination with copper foil, conductive adhesive, or non-woven fabrics for multifunctional integration.