Insulation Systems Engineered for Your Application: Contact Electrolock to discuss your insulation requirements and find the right solution for your design.

How Insulation Tape Failure Shortens Motor Life

Insulation degradation in motor windings doesn’t happen uniformly. It concentrates at specific locations and follows predictable failure paths, each of which is accelerated by underspecified tape materials.

Partial discharge erosion begins when insulation voids or interfaces experience voltage stress above the discharge inception threshold. Once partial discharge activity takes hold, it progressively erodes organic insulation from within, reducing dielectric strength over time until breakdown occurs. Inter-turn shorts occur when insulation tape cannot withstand the combined thermal and mechanical cycling stresses of a motor’s service life, causing the turn insulation to lose mechanical or dielectric integrity. End-winding deterioration accumulates as repeated thermal expansion and contraction work at tape interfaces and adhesive bonds, eventually compromising the structural and electrical integrity of the most exposed part of the winding.

Each of these failure paths is addressable through material selection. Our piece on optimizing coil insulation for motor and generator performance covers how the full coil insulation system works together to manage these stresses, and is useful context for engineers designing from the ground up.

Where High Temperature Tape Lives in a Motor

Understanding which tapes matter most requires knowing where they’re applied and what each location is defending against.

• Turn insulation wraps individual conductors, separating adjacent turns. This is where inter-turn shorts originate when insulation fails, and it’s one of the most thermally stressed locations in the winding.
• Ground wall tape forms the primary dielectric barrier between the wound conductors and the grounded core steel — the layer that must sustain voltage endurance across the motor’s full service life.
• Phase barriers isolate the different phase windings from each other, preventing inter-phase faults that can develop if physical or electrical separation is compromised.
• End-winding protection covers the sections of the winding that extend beyond the core slot, where mechanical stress from vibration and thermal cycling concentrates and where cooling is less effective.

Each location has a distinct stress profile. A tape well-suited to one may be a poor fit for another, which is why motor insulation design requires matching materials to locations, not selecting a single tape for the entire system.

Material Options and What Each Brings to Motor Longevity

Three material families dominate high-temperature insulation tape applications in motor windings, each with a distinct contribution to service life.

Nomex® (aramid paper) delivers Class H thermal performance with the mechanical toughness and conformability that phase insulation and conductor wrap applications demand. Its ability to maintain protective properties under the physical stresses of coil forming and insertion means the insulation arrives at the operating stage intact. Degraded insulation at installation is a lifespan problem that starts before the motor runs its first hour.

Polyimide film (Kapton®) provides the highest dielectric performance per unit of thickness in the lineup, with continuous thermal capability well beyond Class H. For turn insulation in high-voltage, high-power density motor designs where space is a binding constraint, polyimide allows engineers to achieve required dielectric performance in the thinnest possible profile — maximizing copper fill without sacrificing the voltage endurance the winding needs to reach design life.

Mica-backed composite tapes anchor the ground wall insulation system. Mica’s inorganic structure preserves dielectric strength and resists partial discharge under sustained voltage stress, directly countering the erosion mechanisms that degrade organic insulation materials. Electrolock’s high-voltage insulation materials range covers the full spectrum of mica tape constructions for motor applications. For a broader overview of high-temperature tape materials across applications beyond motors, our piece on heat-resistant electrical tape provides useful context.

The Role of Thermal Class in Tape Selection

Every tape in a motor winding system must be rated for the thermal class the system is designed to operate within. Operating above a tape’s rated class — even intermittently under peak load conditions — accelerates every failure mode simultaneously. Partial discharge resistance degrades faster. Mechanical properties deteriorate sooner. Adhesive systems soften and lose bond strength. The cumulative result is a motor that fails well short of its design life without any single dramatic failure event.

Standards such as IEC 60034-18-1, which governs functional evaluation of insulation systems for rotating electrical machines, establish the framework for validating that a system performs to its rated thermal class under real operating conditions — not just under initial test conditions. Our piece on form-wound coil insulation and Class H requirements covers the system-level implications of thermal class designation in detail.

Manufacturing and Process Considerations

A tape that performs well on a datasheet but causes production problems introduces lifespan risk before the motor ever operates. Poor conformability at conductor crossover points leaves voids that become partial discharge sites. Inconsistent tape tension during application creates uneven insulation thickness that concentrates voltage stress. The wrong slit width for the taping machine causes application defects that compromise the ground wall uniformity, as the dielectric performance specification assumes.

These aren’t edge cases. They’re common sources of premature motor insulation failure, and they’re entirely addressable through tape selection and manufacturing process alignment. Electrolock’s testing and validation capabilities extend to process qualification, ensuring that selected tapes perform as designed, not just in the lab but on the production floor.

Partner With Electrolock on Your Motor Insulation Tape Needs

With more than 65 years of experience engineering insulation solutions for high-voltage motors and generators, Electrolock approaches tape selection as a lifespan engineering decision — one that encompasses material performance, thermal class compatibility, system integration, and manufacturing process fit.

Contact Electrolock to discuss your motor insulation requirements, or explore our full range of high-voltage insulation materials to see what’s available.

Partner With Engineering Experts: Connect with Electrolock’s team to begin developing custom electrical insulation solutions engineered specifically for your application requirements.

The Problem With Thinking About Insulation Materials in Isolation

Motor winding failures don’t all originate from the same place. Dielectric breakdown at the ground wall, turn-to-turn shorts at conductor crossover points, and structural delamination under thermal cycling are three different problems — and they require three different material solutions. Selecting one strong performer without accounting for the others leaves the system exposed to the failure modes that the material doesn’t address.

A complete motor winding insulation system integrates multiple materials, each positioned to handle the stress it’s best suited for. Our piece on optimizing coil insulation for motor and generator performance outlines the full eight-component system and how these elements interact and remains a useful reference for engineers designing from the ground up. Standards such as IEC 60034-18-1, which covers functional evaluation of insulation systems for rotating electrical machines, reflect how seriously the industry treats system-level performance rather than individual material ratings.

Mica — The Dielectric and Voltage Endurance Backbone

Mica is the primary dielectric material in motor winding insulation. It serves well in the layer between the copper conductors and the grounded core steel, preventing electrical breakdown under sustained high-voltage stress. Its inorganic crystalline structure provides dielectric strength and resistance to partial discharge, the progressive failure mode that erodes organic insulation from the inside over time. Unlike polymer-based materials, mica does not degrade meaningfully under sustained electrical stress, making it the material of choice for ground wall insulation in both VPI and resin-rich motor coil systems.

In practice, mica appears in multiple forms within the winding: as ground wall tapes in the Poroband® and Porofab® families for VPI applications, as mica paper carrier in conductor insulation tapes, and as the functional insulating layer within corona suppression systems. The high-voltage insulation materials product range reflects how central mica is to every stage of motor coil construction. For engineers designing to Class H thermal requirements, the dielectric and thermal stability of mica ground wall tapes is foundational; this connection is explored in depth in our piece on form-wound coil insulation and Class H requirements.

Fiberglass — Mechanical Reinforcement and Structural Integrity

Fiberglass performs a role in motor winding insulation that’s easy to underestimate because it rarely appears as a standalone product. Instead, it serves as the structural backbone that enables other materials to function as designed. In mica tape constructions across the Poroband®, Porofab®, and Contaglas® families, non-alkaline fiberglass cloth gives the tape its mechanical handling strength, prevents mica particle loss during the taping process, and maintains dimensional stability through the impregnation cycle.

In VPI winding systems, fiberglass also appears in Poromat® swelling mat constructions — glass mat laminates used as spacers and interlayer fillers that expand during resin impregnation to fill voids and ensure complete penetration throughout the winding. This is what fiberglass is protecting against: delamination caused by poorly impregnated voids, structural collapse under coil compression, and the resin penetration failures that leave insulation systems mechanically unsound regardless of their electrical properties. A winding that cures with voids will fail prematurely under thermal cycling, and fiberglass carrier construction is one of the primary engineering controls that prevents that outcome.

Kevlar® — Cut-Through and Puncture Resistance at Stress Points

Kevlar addresses a failure mode that neither mica nor fiberglass is designed to handle: mechanical cut-through and puncture under compression and shear stress. In VPI stator coils, conductor crossover points are where turn-to-turn shorts most commonly originate. These locations are where conductors transition between positions, and the mechanical stress concentrations can cut through conventional insulation materials under the pressures of coil forming and operation.

Electrolock’s Keveloc® and Kevenex® laminates bring Kevlar’s exceptional tensile and shear puncture resistance to these specific locations, applied during pre-consolidation as barrier inserts at the crossover points that need them most. The result is a dramatic reduction in turn-to-turn short risk at precisely the locations where standard insulation is most vulnerable. The full technical case for Kevlar in motor winding insulation is covered in detail in our dedicated piece on Kevlar insulation for motor applications.

How These Materials Work Together

In a well-engineered VPI motor winding, mica handles the electrical stresses that would otherwise cause dielectric breakdown and partial discharge degradation. Fiberglass provides the structural framework that allows resin to penetrate and cure correctly, preventing the voids and delamination that shorten coil life. Kevlar protects the mechanical stress concentrations at crossover points that neither mica nor fiberglass can adequately defend against. None of these materials substitutes for the others; each addresses a failure mode that the other two don’t reach.

That’s the engineering insight that gets lost when materials are evaluated in isolation or selected primarily on cost. The full range of Electrolock’s motor insulation materials — including the mica tape families, fiberglass-backed constructions, and Kevlar laminates discussed here — is available on our motor product table. For engineers navigating a complex coil insulation project, our piece on motor insulation solutions outlines what to look for in an engineering partner who understands the full system.

Partner With Electrolock on Your Motor Winding Insulation Needs

With more than 65 years of experience engineering insulation solutions for motors and generators across power generation, industrial, and automotive applications, Electrolock brings the full-system perspective that demanding motor winding applications require. Our engineers work through every layer of the insulation stack alongside yours, from mica ground wall selection through fiberglass-backed tape constructions to Kevlar barrier inserts at the stress points that matter most.

Contact Electrolock to discuss your motor winding insulation requirements, or explore our full range of high-voltage insulation materials to see what’s available.

Insulation Systems Engineered for Your Application: Contact Electrolock to discuss your Class H coil insulation requirements and find the right solution for your motor design.

What Class H Actually Means

Class H is a thermal designation defined under IEC 60085, the international standard governing thermal evaluation and classification of electrical insulation. It identifies an insulation system rated for continuous operation at elevated temperatures — specifically, a maximum continuous operating temperature of 180°C. But the designation carries a critical implication that’s easy to overlook: Class H is a system rating, not a material rating.

Every component in the coil insulation system — ground wall tapes, slot liners, phase insulation, conductor insulation, corona suppression materials, and the impregnation resin — must be thermally compatible with Class H requirements. A single underspecified component can compromise the thermal class of the entire system, regardless of how well every other element performs. That system-level thinking is what separates a genuinely Class H coil from one that merely contains Class H-rated materials.

Why Form-Wound Coils Demand Class H

Form-wound coils in medium and high-voltage motors operate under a combination of electrical and thermal stresses that lower thermal class systems cannot sustain across a working service life. High voltage stress concentrates heat in compact slot geometries, and the cumulative effects of thermal cycling — repeated heating and cooling through load variations — progressively degrade insulation systems that lack the thermal stability to absorb those stresses over time.

For motors operating in power generation, heavy industrial drives, and traction applications, Class H has become the practical baseline for serious high-voltage coil design. Our overview of advancements in motor coil insulation covers the broader context of how modern insulation systems have evolved to meet these demands, and our piece on insulation for form-wound stator coils examines how insulation choices directly affect power output and efficiency.

Material Requirements for a Class H Coil System

Achieving Class H performance in a form-wound coil requires materials that maintain their electrical, thermal, and mechanical properties at sustained elevated temperatures — across the full service life of the motor, not just under initial test conditions.

Mica-based ground wall tapes form the thermal and dielectric backbone of any Class H coil system. Mica’s inorganic crystalline structure maintains dielectric strength and dimensional stability at temperatures that degrade organic insulation materials, making it the standard choice for ground wall insulation in high-voltage form-wound coils. It is the component that most directly enables Class H compliance at the ground wall level.

Polyimide-backed conductor insulation provides the Class H-rated turn insulation needed at the conductor level. Kapton®/polyimide systems are rated for continuous operation at Class H temperatures and above, making them well-suited to the high thermal stress environments of high-voltage motor windings.

Class H-rated slot liners are a system requirement, not an optional upgrade, in high-voltage form-wound motor applications. The slot liner sits between the winding and the grounded core steel, and any degradation at that interface under sustained heat compromises both dielectric protection and the thermal pathway from windings to core. The material trade-offs involved in slot liner selection for Class H applications — including Nomex®/polyimide composite constructions — are covered in detail in our piece on slot liner insulation and motor efficiency.

Corona suppression tapes must maintain their defined resistance characteristics at Class H temperatures. Degradation of corona suppression materials accelerates partial discharge activity at the slot exit and end-winding regions. This is a failure mode that shortens coil life regardless of how well the ground wall and conductor insulation perform.

System Compatibility is Often Overlooked

Assembling Class H-rated components does not automatically produce a Class H motor insulation system. Material compatibility — particularly between insulation tapes and the impregnation resin system — is a requirement that is frequently underestimated. A Class H-rated tape applied with a Class F-rated resin does not yield a Class H insulation system. The resin must cure fully, penetrate the insulation layers uniformly, and maintain its mechanical and thermal properties at Class H operating temperatures alongside every other material in the system.

This compatibility requirement is one of the most common sources of premature insulation failure in high-voltage motors, and one of the clearest arguments for working with an engineering partner who understands the full system. Our piece on optimizing coil insulation for motor and generator performance addresses how the individual components of a complete coil insulation system interact, and why that interaction matters as much as any individual material choice.

Validation Against Class H Requirements

Class H ratings must be earned through testing, not assumed from material datasheets. Thermal endurance testing, voltage endurance testing, and thermal cycling protocols establish whether a system performs as designed under sustained operating conditions. Electrolock’s testing and validation capabilities support this process in-house, giving engineering teams the data needed to validate system performance before production commitments are made.

Partner With Electrolock on Your Class H Insulation System

With more than 65 years of experience in engineering insulation solutions for high-voltage motors and generators, Electrolock brings the full-system perspective that Class H coil design demands. From ground wall tapes and conductor insulation to slot liners, corona suppression, and resin system compatibility, our engineers work through every layer of the system alongside yours.

Contact Electrolock to discuss your Class H insulation requirements, or explore our full range of high-voltage insulation materials to see what’s available.

Partner With Engineering Experts: Connect with Electrolock’s team to begin developing custom electrical insulation solutions engineered specifically for your application requirements.

What Slot Liner Insulation Does

The slot liner sits at one of the most critical interfaces in a motor’s stator: between the copper windings and the grounded core steel. Its job is more than simple electrical isolation. A well-engineered slot liner provides four distinct functions simultaneously — dielectric protection against voltage breakdown between conductors and core, mechanical protection against abrasion damage during coil insertion, a thermal pathway that facilitates heat transfer from the windings out to the core, and positional stability that keeps conductors properly seated within the slot throughout the motor’s service life.

Each of those functions places demands on the material that can pull in different directions. That’s what makes slot liner insulation a genuine engineering problem rather than a catalog selection. Electrolock’s high-voltage insulation materials portfolio addresses all four functional requirements across a range of motor types and applications.

How Material Choice Affects Motor Efficiency

The connection between slot liner material and motor efficiency runs through one fundamental relationship: thinner insulation with equivalent dielectric performance means more copper in the slot. More copper means higher current-carrying capacity and higher power output from the same motor frame size. Every fraction of a millimeter recovered through smarter material selection translates directly into motor performance.

But wall thickness is only one part of the equation. A thin slot liner that is thermally resistive traps heat in the windings, accelerating insulation degradation and reducing motor efficiency over time. A mechanically fragile thin slot liner may fail during automated conductor insertion, driving up scrap rates and production costs. The material that optimizes all three variables — thickness, thermal performance, and mechanical durability — is the one that genuinely improves motor efficiency. Electrolock’s earliest work in this space, detailed in our piece on custom slot liners for hairpin motors, established the framework for how we approach these trade-offs.

Primary Material Options for Slot Liner Insulation

Three material families dominate slot liner applications, each with a distinct performance profile.

Nomex® (aramid paper) is the workhorse of the category. Rated for Class H thermal performance, Nomex offers excellent toughness, reliable dielectric strength, and strong abrasion resistance. These are all properties that make it well-suited to traditional wound motor applications and to hairpin motor designs where conductors must be physically inserted and twisted without damaging the liner. Electrolock supplies Nomex slot liners in both shaped and slit forms, customized to the dimensional requirements of each motor design.

Polyimide film (Kapton®) delivers the highest dielectric performance per unit of thickness of any common slot liner material, with continuous operating capability well beyond 200°C. For applications where space is the binding constraint and voltage stress is high, polyimide film allows engineers to achieve the required dielectric performance in the thinnest possible profile — maximizing copper fill without compromising electrical integrity.

Nomex®/Polyimide composite is Electrolock’s flagship slot liner construction, combining the mechanical toughness of Nomex with the dielectric performance of polyimide in a spiral wound tube engineered to extremely tight dimensional tolerances. Designed specifically for high-voltage, high-temperature hairpin EV and HEV motor applications, this construction can withstand the dielectric stress, sustained heat, and mechanical abuse of conductor insertion and twisting — all while delivering the thin wall profile that hairpin motor designs demand. Full product specifications are available on our hairpin motor product table.

Matching Material to Application

The right slot liner material depends on the specific demands of the motor. Aspects such as voltage class, thermal rating, motor geometry, and manufacturing process all factor into the decision. Traditional form-wound motors and modern hairpin EV motors present different insertion dynamics, different electrical stress profiles, and different chemical exposure requirements. A material well-suited to one may be a poor fit for the other.

For engineers working specifically on EV and HEV hairpin motor applications, our piece on custom motor slot insulation for electric vehicle applications covers the EV-specific considerations — ATF chemical compatibility, thermal cycling durability, and custom laminate constructions — in greater depth.

The Role of Testing and Validation

Material selection is the starting point, not the finish line. Dielectric breakdown voltage, partial discharge inception voltage (PDIV), thermal cycling endurance, and abrasion resistance all need to be validated against the actual operating conditions of the motor before production commitments are made. Insulation system evaluation for rotating electrical machines is governed by standards such as IEC 60034-18-1, which establishes guidelines for functional evaluation. It’s a framework that underscores why validating materials against real operating conditions matters as much as selecting them. Electrolock’s testing and validation capabilities allow this work to happen in-house, giving engineers the data they need to move forward with confidence.

Partner With Electrolock on Your Slot Liner Insulation Needs

With more than 65 years of experience engineering insulation solutions for motors and generators across power generation, industrial, and automotive applications, Electrolock brings both material depth and application knowledge to every slot liner project. From traditional wound motors to high-voltage hairpin EV designs, our engineers work directly alongside yours to develop the solution that fits — dimensionally, electrically, thermally, and within your manufacturing process.

Contact Electrolock to discuss your slot liner insulation requirements, or explore our full range of high-voltage insulation materials to see what’s available.

Thermal Solutions Engineered for Your Application: Contact Electrolock to discuss high-temperature insulation challenges tailored to your thermal requirements.

What Makes High-Voltage Cable Insulation Different

General-purpose wire insulation manages relatively straightforward electrical loads. High-voltage cable insulation operates in a different category altogether. The primary concerns are dielectric strength — the ability to resist electrical breakdown — and partial discharge resistance, which determines how well the insulation holds up against the localized electrical discharges that occur within voids or at material interfaces under sustained high-voltage stress.

Partial discharge is an insidious failure mode. It doesn’t cause immediate breakdown, but it progressively erodes organic insulation materials from the inside, shortening service life and eventually leading to failure. In high-voltage applications — motors, generators, power cables, and traction systems — this is the failure mechanism that engineers most need to design against.

How Mica Performs as a Dielectric Insulator

Mica’s crystalline structure gives it an inherent advantage in high-voltage environments. Its layered, platelet-like form creates a naturally dense barrier to electrical conduction, resulting in high dielectric strength and, critically, exceptional resistance to partial discharge. Unlike organic polymer materials, mica does not degrade meaningfully under sustained electrical stress; it is inorganic, dimensionally stable, and maintains its insulative properties across a wide range of operating conditions.

Mica-based insulating materials are governed by IEC 60371, the international standard covering their definitions, test methods, and performance specifications. It’s a framework that reflects how seriously the industry takes its electrical properties. This combination of standards and inherent material performance makes mica cable insulation particularly well-suited to applications where voltage endurance over a long service life is the primary design requirement. For engineers who want to understand mica’s equally important role in fire and thermal protection — including its use in EV battery packs — our piece on thermal runaway protection in EV batteries covers that application in depth.

Key Applications for Mica Cable Insulation

The high-voltage wire and cable space encompasses several distinct application categories where mica cable insulation is commonly specified. In traction motor magnet wire, mica tape provides the dielectric protection needed to withstand the voltage stresses inherent in motor drive systems, including the fast-switching transients generated by modern power electronics. In downhole pump motors and cables, mica insulation must maintain performance in chemically harsh, high-temperature environments where conventional materials fail. Power and control cables in industrial and mass transit installations rely on mica for both its dielectric properties and its ability to maintain circuit integrity under fire conditions.

These applications share a common thread: they demand insulation that performs reliably over time, not just under initial test conditions.

Fire Survival Performance — A Complementary Strength

Dielectric performance is mica’s primary value in high-voltage cable applications, but its fire survival properties make it uniquely capable across a broader range of cable types. Electrolock’s Pyrodox® mica cable tapes are engineered for applications requiring both sustained electrical performance and the ability to maintain circuit integrity during a fire event. For a detailed look at Pyrodox® fire survival performance, construction variants, and UL certification capabilities, our piece on high-temperature cable insulation with mica cable tape covers that ground thoroughly.

Selecting the Right Mica Cable Insulation

Not all mica cable insulation is engineered the same way, and the right configuration depends on the specific demands of the application. Key variables include mica type — phlogopite and muscovite offer different balances of thermal and electrical properties — backing material, binder chemistry, tape construction, and slit width. These choices affect everything from how the tape handles during manufacturing to how it performs under voltage stress in service.

Electrolock’s engineers work directly with cable manufacturers and design teams to navigate these variables, drawing on a broad material library and comprehensive testing capabilities to validate performance before production commitments. For a broader look at how mica compares to other insulation material families, our overview of types of electrical wire insulation provides useful context.

Partner With Electrolock on Your Mica Cable Insulation Needs

With more than 65 years of engineering insulation solutions for high-voltage wire and cable applications, Electrolock brings both material depth and application knowledge to every project. Whether the challenge is voltage endurance in a traction motor system, dielectric performance in a downhole cable, or fire survival in a critical power circuit, our team works alongside yours to develop the right solution.

Contact Electrolock to discuss your wire and cable insulation requirements, or explore our full range of high-temperature wire and cable solutions to see what’s available.

Partner With Engineering Experts: Connect with Electrolock’s team to begin developing custom electrical insulation solutions engineered specifically for your application requirements.

What Is Cell Pack Insulation?

Cell pack insulation refers to the materials and barriers integrated throughout an EV battery pack to protect individual cells, isolate them from one another, and shield the pack structure from the consequences of a cell failure. It spans everything from thin dielectric wraps around individual cells to rigid barriers separating modules and flame-resistant linings at the pack perimeter.

While the term “battery insulation” is broad, cell pack insulation is specifically concerned with the architecture of protection inside the pack. It integrates how each layer contributes to overall safety, and how those layers interact under normal and extreme operating conditions. Explore Electrolock’s battery insulation solutions to get a sense of how wide that product range actually is.

Protection at the Cell Level

The first layer of defense begins at the individual cell. Jelly roll wraps create a dielectric barrier between the cell’s internal winding and its outer can. Top and bottom insulators isolate the cell’s terminals from adjacent components. Cell sleeves and pouches provide an additional layer of protection against shorts and physical damage during assembly and operation.

At this level, the primary concern is electrical isolation — preventing a fault condition within one cell from immediately conducting to its neighbors. Material choices here are driven by the need for thin profiles, reliable dielectric strength, and compatibility with automated manufacturing processes.

Protection at the Module Level

Once cells are grouped into modules, the insulation challenge shifts. The threats at this level include cell-to-cell electrical contact and, critically, the spread of heat and flame from a cell that has entered thermal runaway. Tab and lead insulation protect the connection points where cells link to the module’s electrical architecture. Cell-to-cell and cell-to-module barriers form physical boundaries between individual cells and between cell groups.

This is where thermal propagation becomes the dominant design consideration. Standards such as UL 9540A — which evaluates thermal runaway fire propagation at the cell, module, and unit level — underscore just how seriously the industry treats the challenge of containing a failure once it begins. A properly engineered barrier at the module level can slow or stop the cascade of a thermal event from spreading across the pack. For a detailed look at barrier materials and how to evaluate them for your application, our piece on thermal propagation barriers and energy storage safety covers the material selection process in depth.

Protection at the Pack Level

The outermost layer of cell pack insulation addresses what happens if a thermal event is not fully contained at the cell or module level. The interior perimeter walls of the battery pack, the pack lid, and components like busbars and wire harnesses all require insulation that can withstand the heat, gas, and ejecta produced during a severe thermal runaway event.

Pack-level barriers must perform under the most extreme conditions the battery may ever experience. Electrolock’s Go-Therm Thermal Runaway Barrier is one example of a solution engineered specifically for this environment; it’s designed to protect the pack interior from the intensity of a full cell venting event while remaining fabricable into the custom shapes and dimensions that each unique pack requires.

Why Space Constraints Shape Every Decision

What makes cell pack insulation genuinely challenging is that every layer of protection competes for space inside a pack that has none to spare. Thinner materials mean more room for active cell material, which directly affects energy density. But thinner materials must still meet dielectric, flame, and structural requirements, often simultaneously.

This is where the engineering partner relationship matters most. Selecting the right material is only part of the problem. Fitting it into the available geometry, qualifying it against the pack’s specific safety requirements, and ensuring it integrates with the manufacturing process are equally important. Electrolock’s engineers work through all of these variables alongside the customer’s own team.

Partner With Electrolock on Your Cell Pack Insulation Needs

With more than 65 years of experience in engineering insulation solutions for battery systems, Electrolock brings a full-system perspective to cell pack insulation challenges. From individual cell wraps to pack-level thermal-runaway barriers, our team helps engineers find the right solution for each layer and its constraints.

Contact Electrolock to discuss your battery pack insulation requirements, or explore our full range of battery insulation solutions to see what’s available.

Lithium-ion batteries power everything from smartphones to industrial equipment, and the fundamentals for preventing thermal runaway in lithium-ion batteries apply across all of them. Understanding how to prevent thermal runaway in lithium-ion batteries starts with recognizing that not all applications carry the same risk profile. But EV applications introduce a level of complexity that general prevention strategies alone can’t address. The scale, the consequences, and the engineering constraints are categorically different — and the insulation solutions need to be as well.

Thermal Solutions Engineered for Your Application: Contact Electrolock to discuss high-temperature insulation challenges tailored to your thermal requirements.

Why EV Batteries Face Unique Thermal Runaway Challenges

A consumer battery pack contains a handful of cells. An EV battery pack contains hundreds to thousands, storing tens of kilowatt-hours of energy in a confined space optimized for vehicle packaging and weight. When a single cell enters thermal runaway in that environment, temperatures can exceed 1200°C with molten metal ejecta and pressurized gas released in milliseconds. Without properly engineered barriers, cell-to-cell propagation can occur in under 60 seconds.

The consequences extend well beyond battery damage. Vehicle occupant safety, total vehicle loss, and the reputational stakes for automotive OEMs make thermal runaway protection a foundational engineering requirement — not an afterthought. At the same time, EV design imposes hard constraints: every millimeter of insulation thickness competes with energy density, and every gram affects driving range. This is the central challenge: maximum protection with minimum space and weight penalty.

Performance Requirements for EV Thermal Runaway Insulation

Meeting this challenge means evaluating insulation materials across four dimensions simultaneously.

Thermal performance is the most obvious requirement. Materials must withstand temperatures of 800–1200°C or higher without structural failure, maintain low thermal conductivity to slow heat propagation between cells, and carry UL 94 V-0 fire resistance or better. Critically, they must perform during a thermal event, not just under normal operating conditions.

Mechanical requirements are equally demanding. Pouch cells expand and contract during every charge cycle, requiring insulation materials that can manage compression without degrading. All formats require dimensional stability through years of thermal cycling, impact resistance for collision scenarios, and durability across a vehicle’s 10–year service life.

Electrical properties cannot be overlooked in high-voltage EV packs. Dielectric strength is essential for voltage isolation, and any failure in electrical insulation can itself trigger the thermal events that the barriers are designed to contain. See Electrolock’s high-voltage insulation solutions for how electrical and thermal protection intersect.

Finally, design constraints drive real-world material selection. High-volume automotive manufacturing demands insulation that is thin, lightweight, cost-effective at scale, and compatible with automated production processes.

Material Solutions for EV-Scale Thermal Protection

Mica-Based Barriers

For EV applications, mica is the most capable dual-function solution available. It withstands continuous temperatures above 1000°C, provides exceptional dielectric strength for high-voltage isolation, and can be engineered to fit specific cell configurations — cylindrical formats like 18650, 21700, and 4680, as well as pouch and prismatic cells. Electrolock’s mica solutions and Go-Therm Thermal Runaway Barrier are specifically designed for the demands of automotive battery systems. Explore the full range of battery insulation solutions.

Glass Fiber Composites

Glass fiber materials offer excellent flame resistance with structural integrity that holds up under compression, making them particularly well-suited for pouch cell applications where materials must manage cell expansion without losing protective function. Electrolock’s Pyrel-Therm product line addresses extreme heat environments where glass fiber composites are the right engineering fit.

Engineered Laminates

The most demanding EV applications often require a multi-layer approach: combining thermal insulation, flame barriers, compression management, and in some cases heat-spreading foils into a single engineered stack. This approach optimizes performance while minimizing overall thickness, which is a critical advantage in space-constrained pack designs. The specific material stack is matched to cell chemistry, format, and pack architecture.

Engineering the Right Solution for Your EV Battery Design

Cell format shapes everything when determining how to prevent thermal runaway in lithium-ion batteries at the EV scale. Cylindrical cells can accommodate rigid barriers or foam encapsulation. Pouch cells require flexible, compressible materials that accommodate breathing through charge cycles. Prismatic cells can work with rigid or semi-rigid solutions depending on pack design.

Beyond material selection, performance validation is essential. Electrolock’s testing capabilities allow engineers to validate critical parameters — propagation delay time, temperature resistance, and structural integrity — under actual thermal runaway conditions rather than relying solely on material data sheets.

Cell chemistry, pack energy density targets, vehicle packaging constraints, and manufacturing processes all factor into the final specification. This is why Electrolock works with OEMs from the design phase through production, bringing 65+ years of materials engineering expertise to the specific realities of automotive development.

Building Safer EVs from the Inside Out

Knowing how to prevent thermal runaway in lithium-ion batteries at EV scale means recognizing that protection is not a single material decision; it is a system engineering challenge. High-performance insulation for EV applications must simultaneously manage extreme heat, maintain electrical isolation, survive mechanical demands, and fit within aggressive space and weight budgets. Getting it right requires matching materials to your specific application with precision.

Contact Electrolock to discuss your EV battery thermal protection requirements and find the engineered solution your design demands.

Selecting the right high temp insulation material requires more than finding something that won’t melt. In many demanding applications — motor windings operating above 200°C, EV battery packs with high-voltage isolation requirements, industrial furnace equipment — engineers need materials that simultaneously manage heat and maintain electrical integrity. While we’ve previously explored general thermal insulation properties, high-temperature applications introduce a critical layer of complexity: the dual-property challenge.

Here, we’ll explore a variety of high temp insulation materials through that twin prism.

Partner With Engineering Experts: Connect with Electrolock’s team to begin developing custom electrical insulation solutions engineered specifically for your application requirements.

Why High-Temperature Applications Require Dual-Property Analysis

A material that performs well thermally may fail electrically — and vice versa. Ceramics, for example, can handle extreme temperatures but offer limited dielectric performance. Conversely, some polymer-based insulations provide strong electrical isolation but degrade quickly above moderate temperatures. When both properties are required simultaneously, material selection becomes a precision engineering decision, not a catalog purchase.

The four properties that matter most are thermal performance (operating temperature range, thermal conductivity, fire resistance), dielectric performance (voltage isolation capability, dielectric strength measured in kV/mm), mechanical stability (dimensional consistency, flexibility, durability under cycling), and chemical resistance (moisture absorption, compatibility with process chemicals).

High Temp Insulation Material Comparison

PET (Polyester) — The Baseline

PET is the entry point of this conversation, not a true high-temp material, but useful as a baseline. With a thermal ceiling around 130°C and good dielectric strength, PET works well for battery cell insulation and moderate-temperature electrical components. It’s cost-effective and flexible, but once operating temperatures climb above 130°C, engineers need to move up the material spectrum. Learn more about PET applications in battery insulation.

Nomex® (Aramid) — Moderate High-Temp Range

Nomex® extends the temperature ceiling to 220°C in continuous operation while adding meaningful mechanical strength and flame resistance. With a dielectric strength of 35 kV/mm, it handles a wide range of electrical applications, including motor phase insulation and transformer components. Its primary limitations are moisture absorption and its inability to perform in applications pushing beyond the high-temp threshold. For applications in that 130–220°C window where mechanical durability matters, Nomex® is a reliable performer.

Fiberglass — Cost-Effective Through 600°C

Fiberglass bridges the gap between moderate and true high-temperature performance, operating up to 600°C in continuous service. With dielectric strength ranging from 19–24 kV/mm, it handles medium-voltage applications adequately. Its combination of thermal performance, dimensional stability, and cost-effectiveness makes it a standard choice across HVAC, industrial motors, and general industrial applications where extreme voltage isolation is not the primary requirement.

Mica (Muscovite and Phlogopite) — The Dual-Property Standard

For applications demanding simultaneous high-temperature and high-voltage performance, mica is the benchmark. Muscovite mica handles 500–700°C continuous operation; phlogopite extends that range to 800–1000°C for the most extreme environments. Both deliver exceptional dielectric strength in the range of 118–140 kV/mm — performance no polymer-based system can match at equivalent temperatures.

This combination makes mica the go-to material for high-voltage motor and generator ground wall insulation, EV battery thermal barriers requiring voltage isolation, and fire-survival cable applications. It can be engineered into flexible tapes, rigid panels, or molded shapes, giving designers significant flexibility. Explore high-voltage insulation solutions and battery insulation applications where mica is commonly specified.

Ceramic — Extreme Heat, Specialized Role

Ceramic materials reach the highest temperature ceilings — 1000–1260°C and beyond — making them indispensable for furnace linings, aerospace heat shields, and exhaust system insulation. However, some ceramic forms exhibit electrical conductivity, which limits their role in applications requiring dielectric performance. Where pure thermal management at extreme temperatures is the priority and electrical isolation is not, ceramic is the top performer.

Material Selection Framework

The temperature zone is the first filter. For the 130–220°C range, PET and Nomex® are practical and cost-effective. From 220–600°C, fiberglass and muscovite mica provide the right balance of performance and value. Above 600°C, phlogopite mica and ceramic are the specialized solutions required.

Electrical requirements then narrow the field further. Applications above 4kV consistently point toward mica due to its unmatched dielectric strength. Where extreme heat and high voltage coexist, mica is often the only practical solution that delivers both without compromise.

Engineer the Right Solution with Electrolock

Since 1957, Electrolock has been engineering high-temperature electrical insulation solutions across motor and generator manufacturing, battery systems, and wire and cable applications. Our engineering team works with clients to evaluate the full performance picture — thermal, dielectric, mechanical, and chemical — rather than optimizing for a single property. We also maintain comprehensive testing capabilities to validate material performance under your specific operating conditions before production commitments are made.

Contact Electrolock to discuss your high-temperature insulation requirements and find the right material for your application.

When temperatures exceed material limits in electrical systems, insulation breaks down, conductors short, and catastrophic failures occur. Heat-resistant electrical tape provides critical defense, but selecting appropriate solutions requires understanding material capabilities and application demands.

Below, we’ll take a look at material types and temperature coverage offered by heat-resistant electrical tapes, and how working with Electrolock can help you identify the best options for your unique application.

Custom Solutions for Your Specific Applications: Reach out to the Electrolock team today to begin discussing your next electrical insulation project.

Understanding Thermal Failure in Electrical Systems

Thermal failure occurs when insulation degrades under sustained or peak temperature exposure. As temperatures rise beyond design limits, polymeric materials soften, dielectric strength diminishes, and mechanical properties deteriorate. Short circuits develop between conductors, electrical arcing ignites surrounding materials, and in critical systems — think emergency circuits, aircraft harnesses, or battery connections — single failures can cascade into system loss.

Heat-resistant electrical tape maintains integrity across extended temperature ranges. A tape rated for 130°C proves inadequate for applications experiencing 300°C or flame exposure. Matching specifications to operating conditions ensures reliable performance.

Key Materials in Heat-Resistant Electrical Tape

Different types of electrical insulation materials deliver distinct thermal capabilities, each suited to specific application requirements.

Mica-Based Tapes

For extreme temperature and fire survival applications, mica-based tapes represent the premium solution. Electrolock’s proprietary Pyrodox® cable tapes combine thin mica paper with halogen-free silicone binders and reinforcing substrates to deliver:

• Continuous operation up to 500°C with peak resistance to 1800°F during fire exposure
• UL 94 V-0 flame rating for fire survival
• Excellent dielectric strength for high-voltage environments

These tapes prove essential for fire-rated circuit integrity cables where emergency systems must remain operational during fire events. Applications include mass transit, aircraft, oil well equipment, and critical infrastructure.

Polyimide Tapes

Polyimide-based tapes — such as brand names Kapton® and Apical® — deliver outstanding thermal stability for continuous high-temperature service. Withstanding temperatures exceeding 500°C (932°F), these high-temperature materials provide exceptional mechanical strength and chemical resistance. Aerospace, military, and satellite applications specify polyimide tapes for extreme environment reliability.

PTFE (Teflon®) Tapes

PTFE tapes offer excellent chemical resistance and dielectric properties alongside temperature capability up to 260°C (500°F). Available in multiple configurations — FEP, PFA, sintered, and unsintered — PTFE tapes deliver flexibility in matching application requirements with broad chemical compatibility.

Nomex® Aramid Tapes

Nomex® tapes combine good thermal resistance (up to 220°C) with exceptional mechanical strength and tear resistance. Their conformability makes them valuable for motor and generator applications requiring phase insulation, conductor wrap, and coil protection. The material withstands the stresses of coil forming and installation while maintaining thermal protection during operation.

Critical Applications for Heat-Resistant Electrical Tape

Wire and Cable Systems

High-temperature wire and cable applications demand insulation maintaining circuit integrity under extreme conditions. Fire survival cables must operate when exposed to flame. Downhole cables encounter sustained heat, mechanical stress, and chemical exposure. Aerospace harnesses face wide temperature swings and vibration.

Pyrodox® mica tapes meet UL 5107, UL 5128, and UL 2196 standards. These tapes can be precision-slit to widths less than 1/8 inch and supplied on traverse-wound spools for high-speed automated wrapping.

Motor and Generator Coils

Electrical machines generate significant heat during operation. Turn insulation, conductor wraps, and phase barriers must withstand thermal loads from electrical losses and potential fault conditions. Heat-resistant tapes protect critical coil regions, particularly crossover points and end windings, where mechanical stress combines with thermal exposure.

Battery Systems and High-Voltage Connections

Modern battery packs and high-voltage systems present unique insulation challenges. Busbar connections require materials combining dielectric strength with thermal resistance. Heat-resistant tapes, particularly mica-based solutions, deliver the electrical isolation and thermal capability required for safe operation.

Industrial Equipment

Manufacturing processes involving heat treat operations, furnaces, or high-temperature curing require harness protection that withstands sustained elevated temperatures. Heat-resistant tapes protect wiring and sensor connections where standard materials would fail within hours.

Selecting the Right Heat-Resistant Tape

Optimal tape selection requires evaluating multiple performance parameters:

Temperature Requirements: Distinguish between continuous operating temperature and peak exposure. A system operating at 200°C but spiking to 400°C during transients requires tape rated for peak exposure. Consider both maximum temperature and duration.

Electrical Requirements: Dielectric strength needs vary dramatically based on voltage levels. Medium and high-voltage applications demand materials with proven voltage endurance and partial discharge resistance. Lower-voltage applications may prioritize flexibility or adhesion.

Mechanical Demands: Application conditions determine required mechanical properties. Does the tape need to conform to irregular surfaces? Must it withstand abrasion during installation or service? Tapes wrapping moving components require different characteristics than those protecting stationary conductors.

Environmental Factors: Chemical exposure, moisture, UV radiation, and flame exposure all influence material selection. Testing and validation under conditions simulating service environments ensure selected tapes perform reliably throughout their service life.

Manufacturing Compatibility: Consider how tapes integrate with production processes. Can they be applied with existing equipment? Are special configurations, like traverse-wound spools or specific widths, required for automated processing? Manufacturing efficiency impacts total system cost significantly.

Engineer Thermal Protection Solutions With Electrolock

Since 1957, Electrolock has engineered insulation solutions for demanding thermal and electrical environments. Our approach extends beyond supplying products; we develop optimized solutions for specific application requirements.

Our Pyrodox® cable tape line offers configurations engineered for distinct applications. Tapes are available in thicknesses less than 0.003 inches, precision-slit to exact specifications, and supplied in formats compatible with automated processes. Our comprehensive testing capabilities validate performance under conditions matching service environments.

From initial material selection through testing and production support, our engineering team partners with clients to achieve reliable thermal protection.

Contact Electrolock today to discuss how heat-resistant electrical tape solutions can prevent thermal failures in your critical applications.

For over a century, mica sheet insulation has remained one of the most reliable materials for managing extreme electrical and thermal demands. Its unique combination of dielectric strength, thermal stability, and mechanical durability makes it indispensable across industries where insulation failure isn’t an option. From high-voltage motors spinning in power generation facilities to battery packs powering electric vehicles, mica sheet insulation continues to prove its value in applications where performance and safety are non-negotiable.

At Electrolock, we’ve spent decades engineering mica-based solutions that leverage this material’s exceptional properties. Whether you need ground wall insulation for a 15kV generator, thermal barriers for industrial furnaces, or custom CNC-machined components for specialized equipment, mica sheet insulation provides the foundation for reliable, long-lasting performance.

Solutions Engineered for Your Application: Contact Electrolock to discuss insulation challenges and mica sheet insulation options tailored to your requirements.

What Makes Mica Sheet Insulation Exceptional

Understanding why mica performs so well requires looking at its fundamental properties. Mica is a naturally occurring mineral with a layered crystalline structure that can be processed into thin, flexible sheets or rigid plates. This structure provides mica with several characteristics that complement the goals of insulation solutions.

Superior dielectric strength allows mica sheet insulation to withstand high voltage stress without breaking down. In high-voltage electrical applications, this translates to reliable insulation that maintains its protective properties over years of continuous operation, even under electrical stress that would degrade polymer-based alternatives.

Exceptional thermal stability means mica maintains its structure and insulating properties at temperatures where most materials would fail. While many insulation materials begin degrading above 200°C, mica sheet insulation remains stable at temperatures exceeding 1,000°C. This makes it ideal for applications involving sustained high heat or thermal events where insulation must continue functioning.

Natural flame resistance provides an additional safety margin. Unlike polymer insulations that melt, burn, or release toxic gases when exposed to fire, mica maintains its barrier properties during thermal events. This characteristic proves critical in fire-survival applications where circuit integrity can mean the difference between controlled shutdown and catastrophic failure.

High-Voltage Insulation for Motors, Generators, and Coils

In medium- and high-voltage rotating machinery, insulation integrity directly determines equipment reliability and service life. Electrolock engineers mica-based insulation systems specifically for these demanding applications, including ground wall tapes that provide the primary electrical barrier between coil windings and grounded stator cores, interturn insulation that prevents breakdown between adjacent coil turns, and precision CNC-machined rotor and stator components that ensure exact fit and optimal performance.

The mica tapes used in these systems typically combine mica paper with backing materials like polyester film or fiberglass, creating composites that balance electrical performance with mechanical durability. When properly applied and cured with compatible resin systems, these tapes create robust insulation systems capable of withstanding both electrical stress and mechanical forces during operation.

Thermal Management and Fire-Resistant Solutions

Beyond electrical insulation, mica sheet insulation excels in thermal management applications where heat control is critical. Engineers specify mica-based materials for heat shields that protect sensitive components from radiant heat in industrial equipment, thermal barriers between hot and cold zones in furnaces and kilns, and structural insulating plates that maintain dimensional stability at elevated temperatures.

In wire and cable applications for high-temperature environments, mica provides essential fire resistance. Electrolock’s Pyrodox® mica-based insulation is specifically engineered for applications where fire survival matters most.

Critical Safety Layers in Battery Systems

As battery energy densities increase, the consequences of thermal runaway events become more severe. Mica sheet insulation plays an increasingly important role in battery safety systems designed to prevent or contain these events. Engineers incorporate mica-based materials as cell-to-cell insulation barriers that provide both electrical isolation and thermal resistance, thermal runaway mitigation layers that slow heat propagation between cells, and custom insulating sleeves and barriers tailored to specific cell geometries and battery pack configurations.

The low thermal conductivity of mica sheet insulation helps contain heat within individual cells during thermal events, buying precious time for battery management systems to respond and for occupants to evacuate safely.

Custom Engineering and Validated Performance

One of the mica sheet insulation’s greatest advantages is its versatility in manufacturing. The material can be cut, formed, laminated, molded, or precision-machined to meet nearly any specification. Electrolock works with customers to produce custom-engineered insulation components, including precision-cut spacers, washers, and gaskets for specific assembly requirements, application-specific insulating plates with complex geometries, and custom composite laminates that combine mica with other materials for optimized performance.

This customization capability extends beyond simple fabrication. Electrolock’s in-house testing services validate that mica-based insulation will perform as specified under actual operating conditions. Dielectric strength testing confirms voltage withstand capability, thermal cycling verifies dimensional stability across temperature ranges, and mechanical testing ensures durability during assembly and operation. This validated approach reduces field failures and gives engineers confidence that materials will perform as designed.

Electrolock: Engineering Mica Solutions Since 1957

Electrolock has been engineering mica-based insulation solutions for nearly seven decades. Our expertise spans the full range of mica applications — from ground wall tapes for multi-megawatt generators to thermal barriers for battery packs. We understand that mica sheet insulation is rarely a drop-in solution; optimal performance requires matching material properties, thickness, backing materials, and resin systems to specific application requirements.

Our engineering team works directly with customers to analyze operating conditions, define performance requirements, and develop solutions that balance electrical performance, thermal management, mechanical durability, and manufacturing considerations. Whether you need standard mica products or completely custom configurations, we bring both material expertise and manufacturing capabilities to deliver solutions that work.

Connect with Electrolock today to discuss your project needs, learn more about our testing services, or request a free sample of mica sheet insulation for your application.

When wire insulation fails in high-heat environments, the consequences extend far beyond a simple electrical short. From industrial motors catching fire on production floors to downhole drilling equipment losing functionality miles underground, inadequate high-temperature wire insulation creates risks that no engineer or facility manager can afford to ignore. In applications where temperatures routinely climb above 200°C, standard wire insulation doesn’t just degrade; it fails catastrophically.

Partner with Insulation Experts: Connect with Electrolock’s team to develop custom electrical insulation solutions engineered specifically for your application requirements.

Understanding High-Heat Environments and Their Electrical Challenges

High-heat environments pose unique challenges for electrical systems. When standard wire insulation encounters sustained temperatures above 90°C, the materials begin to break down, losing both their physical integrity and electrical insulation properties. This degradation manifests as cracking, brittleness, melting, and ultimately, complete failure of the dielectric barrier.

Industries most affected include industrial manufacturing facilities with furnaces and metal processing equipment, automotive applications such as EV traction motors, downhole drilling operations, power generation facilities, and mass transit systems. In each application, wire insulation must withstand not only high temperatures but also vibration, chemical exposure, and mechanical abrasion.

Critical Properties of High Temperature Wire Insulation

Selecting appropriate high temperature wire insulation requires understanding several key performance characteristics.

• Thermal stability ensures materials maintain structural integrity during sustained exposure to elevated temperatures.
• Dielectric strength must remain constant despite thermal stress to prevent electrical breakdown.
• Mechanical durability prevents cracking and brittleness from thermal cycling.
• Chemical resistance protects against oils, solvents, and coolants common in high-heat environments.
• Flame resistance meeting UL standards prevents fire propagation during electrical faults.

High Temperature Wire Insulation Materials: From Teflon to Mica Solutions

Pyrodox® Mica-Based Insulation

For applications demanding ultimate thermal protection and fire resistance, Pyrodox® mica-based insulation stands apart. This material excels in environments where fire survival is absolutely critical — power cables, mass transit systems, oil wells, thermocouples, and shipboard applications where cable integrity during fire events means the difference between controlled evacuation and catastrophe.

Pyrodox® combines exceptional thermal stability with inherent flame resistance, maintaining insulation properties even when directly exposed to fire. The material’s natural crystalline structure provides superior dielectric strength while resisting moisture and industrial chemicals. Unlike polymer-based solutions that melt or burn away, mica-based insulation maintains a protective barrier, preventing fire propagation through electrical systems.

This proprietary material from Electrolock offers distinct advantages where standard materials cannot perform. Its ability to withstand extreme temperatures while providing reliable electrical insulation makes it the material of choice for critical safety systems.

Polyimide Films (Kapton®/Apical®)

Polyimide-based insulation maintains stability at temperatures exceeding 500°C (932°F). These materials combine thermal endurance with excellent mechanical properties and chemical resistance for extreme industrial applications. High dielectric strength ensures reliable electrical isolation even under thermal stress, while mechanical durability resists tearing and abrasion.

PTFE/Teflon® Variants

PTFE-based insulation provides reliable performance at temperatures up to 260°C (500°F) with excellent chemical resistance. PFA represents the strongest PTFE form, withstanding the highest temperatures. Sintered PTFE offers high elongation and weather resistance for wire wrapping. Tensilized PTFE provides enhanced tensile strength for transformers and electrical wire. UnSintered PTFE delivers excellent dielectric properties for cable applications.

Nomex® (Aramid)

Nomex® insulation combines high thermal endurance with mechanical properties and conformability for motor phase insulation, transformer applications, and coil-based systems requiring bulk and flexibility.

Selecting the Right High Temperature Wire Insulation

Choosing optimal insulation requires a systematic evaluation of multiple factors.

• Maximum operating temperature — both continuous and intermittent — defines baseline material requirements.
• Environmental factors, including chemical exposure, moisture, and mechanical stress, significantly impact material selection.
• Voltage requirements dictate the necessary dielectric strength.
• Space constraints often favor materials with superior performance-to-thickness ratios.
• Regulatory compliance ensures installations meet safety codes.
• Cost considerations must balance initial expense against long-term reliability and potential failure consequences.

Off-the-shelf solutions rarely optimize for all variables; custom engineering often proves necessary for specific high-temperature applications. Electrolock has a long history of working with customers to identify these variables and craft bespoke insulation solutions.

Engineer High-Temperature Solutions with Electrolock

Since 1957, Electrolock has been engineering high temperature wire insulation solutions for demanding applications. Our expertise spans multiple material platforms, from our proprietary Pyrodox® mica-based insulation to advanced polymer systems, enabling optimal material selections for specific requirements.

Our engineering team analyzes operating conditions, evaluates performance requirements, and develops custom solutions when standard materials fall short. Electrolock’s comprehensive testing capabilities validate material performance under actual operating conditions, including thermal cycling, dielectric strength testing, and chemical resistance evaluation.

Connect with Electrolock today to discuss your project needs, learn more about our testing services, or request a free sample.

Every manufacturing system presents unique challenges. So why compromise performance with one-size-fits-all tubing? In today’s demanding electrical applications — from high-voltage battery systems to precision motor assemblies — standard catalog products increasingly fall short of meeting the complex performance requirements that engineers face. Custom electrical insulation tubing represents not just an alternative, but often the optimal solution for applications requiring specific combinations of electrical, thermal, mechanical, and chemical properties that off-the-shelf products simply cannot deliver.

Engineering Custom Tubing Solutions is Our Specialty: Connect with Electrolock’s team to explore how spiral wound tubing can solve your most demanding insulation challenges.

The Four Critical Questions That Drive Custom Solutions

At Electrolock, we’ve learned that successful electrical insulation tubing begins with understanding your specific application requirements. Our engineering approach centers on four essential questions that guide the development of optimal solutions:

How Will the Tube Be Used?

Application context determines everything. Battery cell insulation demands different properties than motor lead protection or busbar covering. Understanding the operational environment, voltage levels, and thermal conditions allows us to recommend materials and constructions that align precisely with your needs. Whether protecting high-voltage connections in electric vehicles or insulating sensitive electronics, the application drives material selection.

What Are the Performance Requirements?

Defining performance specifications requires examining multiple properties simultaneously. Electrical requirements include voltage breakdown resistance and dielectric strength — critical factors addressed by industry standards like UL 224, the Standard for Extruded Insulating Tubing. Thermal properties encompass operating temperature ranges, flame ratings, and thermal conductivity. Mechanical demands cover tensile strength, tear resistance, and puncture protection. Chemical considerations include resistance to oils, solvents, and process chemicals. Custom tubing allows optimization across all these dimensions rather than accepting the compromises inherent in standard products.

How Will It Be Installed?

Manufacturing integration significantly impacts tubing selection. We can provide spiral wound tubing in configurations that streamline your production process: cut-to-length parts for manual assembly, continuous rolls for automated equipment, flared ends for easier installation, sealed end caps for moisture protection, or notched cuts for specific geometric requirements. These customizations reduce installation time, minimize errors, and improve overall manufacturing efficiency.

What’s the Budget?

Cost-effectiveness means delivering required performance at an optimal price point, not simply choosing the cheapest option. Our extensive materials knowledge allows us to engineer solutions that meet specifications without over-engineering. Sometimes, a carefully designed composite structure combining materials like PET film, fiberglass backing, and mica layers delivers better value than expensive single-material alternatives. Meeting your cost requirements is as important as meeting your performance requirements.

Material Flexibility Enables Optimal Solutions

The versatility of spiral wound tubing construction allows selection from a broad materials palette. Options include PET (polyester) for cost-effective applications with moderate temperature requirements, Kapton® (polyimide) for extreme temperature endurance, Nomex® (aramid paper) for exceptional mechanical strength, fiberglass for dimensional stability, mica for superior dielectric properties and thermal resistance, and specialized materials like PEEK or Ultem® for demanding chemical environments. We often combine multiple materials in laminated structures, creating tubing that delivers properties no single material could provide alone.

Dimensional flexibility further enhances customization possibilities. Wall thickness ranges from 0.002″ for space-constrained applications to 0.125″ for robust protection. Inside diameters span from 0.050″ for fine wire insulation to 6.0″ for large busbar covering. Length options include short cut pieces, extended lengths, or continuous rolls, depending on your manufacturing process.

The Engineering Partnership Beyond Product Delivery

Custom electrical insulation tubing development extends beyond simply supplying materials. Electrolock’s comprehensive testing capabilities validate that selected solutions perform reliably under your specific operating conditions. We can conduct dielectric strength testing, thermal cycling analysis, mechanical property verification, and chemical resistance evaluation — ensuring materials meet both immediate performance needs and long-term reliability requirements. This validation prevents costly failures and redesigns.

Our engineering support continues through production implementation. We work directly with your manufacturing team to optimize tubing configurations for efficient processing, minimize waste, and ensure consistent quality. Whether developing shrink-tubing applications, non-shrink protective sleeves, or specialty constructions, our goal remains building success from the inside out — recognizing that while insulation remains hidden, it makes all the difference to system performance and safety.

Partner With Electrical Insulation Tubing Specialists

When off-the-shelf products cannot meet your application’s unique demands, custom spiral wound tubing provides the engineering solution. With over 65 years of materials expertise, Electrolock approaches each project by asking the right questions, understanding your specific requirements, and developing tubing solutions optimized for both performance and manufacturing efficiency.

Contact our engineering team to discuss how custom electrical insulation tubing can enhance the reliability and efficiency of your electrical systems.

Modern power systems generate significant heat. Motors run hotter to maximize efficiency. Battery systems manage substantial thermal loads. High-voltage components operate in demanding thermal environments. As electrical equipment pushes performance boundaries, the insulation protecting critical components must reliably withstand increasingly severe operating temperatures. High-temperature tubing serves as essential protection in these applications, but selecting the right solution requires understanding how different materials perform across varying thermal demands.

Thermal Solutions Engineered for Your Application: Contact Electrolock to discuss high-temperature insulation challenges and explore spiral wound tubing options tailored to your thermal requirements.

Moderate Temperature Applications: Balancing Performance and Economy

Many electrical applications operate in what industry standards, such as IEC 60085, define as moderate thermal environments, where the thermal factor is the dominant aging consideration. These conditions demand materials that provide reliable insulation without the cost premium of extreme temperature solutions.

PET-based spiral wound tubing excels in these moderate temperature ranges. The material offers excellent dielectric strength combined with good mechanical durability and chemical resistance. Applications include battery cell insulation in consumer electronics, motor lead protection in standard industrial equipment, and wire harness insulation in automotive systems operating within normal thermal parameters. The cost-effectiveness of PET materials makes them ideal where thermal demands remain within moderate ranges, but electrical isolation and mechanical protection remain critical.

For applications approaching the upper limits of moderate temperature operation, enhanced PET formulations provide extended thermal capability while maintaining economic advantages. These materials serve effectively in applications like electric vehicle battery management systems, where thermal loads fluctuate but rarely reach extreme levels during normal operation.

High Temperature Applications: Where Standard Materials Fall Short

As operating temperatures increase, material selection becomes more critical. Applications in this range — including many motor and generator systems, power distribution equipment, and high-performance battery applications — require materials that maintain both electrical and mechanical properties under sustained thermal stress.

Aramid-based materials, particularly Nomex®, provide exceptional performance in high-temperature environments. These materials offer outstanding thermal endurance for continuous operation, where moderate temperature solutions would degrade. The molecular structure of aramid fibers resists thermal breakdown, maintaining dimensional stability and dielectric strength even under prolonged exposure to heat.

High-temperature spiral wound tubing incorporating aramid materials finds application in Class H motor windings, transformer lead insulation, and industrial equipment operating in elevated temperature environments. The material’s resistance to thermal degradation extends service life and prevents premature failures that would occur with lower-rated insulation.

Fiberglass-reinforced constructions also serve high-temperature applications effectively, particularly where mechanical strength must complement thermal resistance. These composite structures combine the thermal stability of glass fibers with the processing advantages of spiral wound construction.

Extreme Temperature Applications: Demanding the Ultimate Materials

The most thermally demanding applications — high-voltage motors and generators, aerospace systems, and specialized industrial processes — require materials that withstand temperatures where most insulation fails. These extreme environments demand careful material selection based on proven thermal endurance.

Polyimide materials, such as Kapton®, deliver exceptional thermal stability while maintaining the flexibility essential for complex geometries. The aromatic polymer structure resists decomposition at temperatures that would destroy standard insulation materials. Applications include high-performance motor slot insulation, aerospace wire protection, and specialty industrial equipment.

For the most extreme thermal conditions, mica-based solutions provide unmatched temperature resistance. Natural mica maintains structural integrity and dielectric properties at temperatures exceeding most organic materials’ capabilities. Mica-based spiral wound tubing combines the mineral’s thermal stability with flexible construction suitable for motor coils, generator windings, and applications requiring both extreme temperature resistance and dielectric protection.

Composite constructions often provide optimal solutions for extreme temperature applications. Combining materials like polyimide films with mica papers or aramid reinforcements creates insulation systems that address multiple performance requirements simultaneously — thermal stability, dielectric strength, mechanical durability, and manufacturability.

Beyond Temperature Alone: Integrated Performance Requirements

While thermal capability drives high-temperature tubing selection, successful applications require balancing multiple properties. Electrical requirements include dielectric strength and partial discharge resistance. Mechanical demands encompass flexibility, tear strength, and durability during installation. Chemical considerations address compatibility with oils, coolants, and process chemicals. Manufacturing factors include ease of application and compatibility with automated equipment.

Spiral wound construction offers distinct advantages when addressing these integrated requirements. The helical structure provides flexibility that solid sleeves cannot match, allowing tubing to conform to complex geometries. Multiple material layers can be combined within a single construction, optimizing performance across thermal, electrical, and mechanical dimensions. Custom configurations — including sealed ends, reinforced sections, and specialized coatings — address specific application challenges.

Validating Thermal Performance Through Testing

Specifying high-temperature tubing based solely on material data sheets provides incomplete assurance. Actual operating conditions include thermal cycling, mechanical stress, and environmental factors that influence long-term performance. Comprehensive testing capabilities validate that selected materials perform reliably under application-specific conditions.

Thermal aging tests evaluate how materials degrade over extended exposure to elevated temperatures. Thermal shock testing assesses resistance to rapid temperature changes. Dielectric testing at elevated temperatures confirms that electrical properties remain adequate throughout the thermal range. These validation procedures prevent costly failures and ensure specified insulation delivers the expected service life.

Engineering High Temperature Solutions

Selecting optimal high temperature tubing requires understanding both material capabilities and application demands. Whether addressing moderate thermal loads with cost-effective PET solutions, high temperature requirements with aramid or fiberglass constructions, or extreme conditions demanding polyimide or mica materials, matching thermal performance to application needs ensures reliable, economical insulation systems.

Connect with Electrolock’s engineering team to discuss your high temperature insulation challenges and explore how custom spiral wound tubing solutions can deliver the thermal performance your application demands.

Not every electrical insulation challenge fits neatly into standard product categories. When applications demand specific combinations of thermal performance, dielectric strength, mechanical durability, and dimensional constraints — often within tight manufacturing tolerances and cost parameters — custom electrical insulation becomes essential rather than optional. These situations signal the need for an engineering partner rather than simply a product supplier.

Standard products fail when geometric complexity demands precise conformability, when multiple performance requirements conflict, when extreme operating conditions exceed catalog specifications, or when manufacturing processes require specialized configurations. If your application involves any of these challenges, custom electrical insulation development offers the pathway to best-fit solutions.

Partner With Engineering Experts: Connect with Electrolock’s team to begin developing custom electrical insulation solutions engineered specifically for your application requirements.

Discovery: Understanding Your Complete Requirements

Effective custom electrical insulation development begins with application analysis. This discovery phase examines not just the obvious specifications, but the complete operational context that influences insulation performance.

Environmental factors include operating temperature ranges, exposure to chemicals or moisture, voltage levels, stress distribution, mechanical loading and vibration, and thermal cycling patterns. Performance requirements encompass dielectric strength needs, thermal management objectives, mechanical property demands, flame resistance specifications, and dimensional tolerances. Manufacturing considerations address installation methods, automation compatibility, production volume implications, and quality verification procedures.

This thorough discovery prevents the costly mistakes that occur when insulation solutions address only partial requirements. Understanding the complete picture, including constraints that may seem secondary but prove critical during implementation, enables the development of solutions that perform reliably throughout their service life.

Engineering: Translating Requirements Into Solutions

With requirements clearly defined, the engineering phase translates specifications into practical insulation system designs. This process draws upon extensive materials knowledge, proven design methodologies, and comprehensive testing capabilities.

Material selection for custom electrical insulation systems requires balancing multiple properties simultaneously. According to UL 1446, electrical insulation systems comprise unique combinations of materials verified for chemical compatibility when used at certain maximum temperatures. Engineers must consider not only individual material properties but also how components interact within the complete system.

Solution design services integrate material expertise with application knowledge. For battery insulation applications, this might involve combining materials for dielectric protection, thermal management, and mechanical support within extremely tight dimensional envelopes. For high-voltage applications, the design addresses voltage stress distribution, partial discharge resistance, and thermal stability. For specialty spiral wound tubing, engineers optimize layer configurations, dimensional specifications, and end-finish details.

Testing and validation confirm that proposed solutions meet specifications under actual operating conditions. Comprehensive analytical testing examines thermal properties, electrical characteristics, mechanical behavior, and chemical resistance. High-voltage testing validates dielectric performance, partial discharge inception levels, and voltage endurance. This empirical validation prevents failures that theoretical analysis alone cannot predict.

Implementation: From Prototype to Production

Successful custom electrical insulation development extends beyond design. It also requires seamless transition into manufacturing. Implementation phase services ensure solutions that perform excellently in testing also succeed in production environments.

Manufacturing services transform engineered designs into production-ready components. Capabilities include precision slitting and rewinding for exact dimensional control, coating and saturation for enhanced performance properties, laminating for composite structures, and punching or rotary die cutting for complex geometries. These converting processes adapt materials to specific application requirements while maintaining the quality standards essential for reliable insulation performance.

Production implementation also addresses practical manufacturing considerations. Custom configurations might include cut-to-length parts for manual assembly operations, continuous rolls for automated equipment, specialized packaging for contamination-sensitive applications, or quality documentation for traceability requirements. These details — often overlooked until production begins — significantly impact manufacturing efficiency and final product quality.

Quality assurance throughout production ensures consistent performance. Statistical process controls, dimensional verification, electrical testing protocols, and material certification documentation provide confidence that production components match prototype performance. This consistency proves critical in applications where insulation failures create safety risks or operational disruptions.

Explore the Breadth of Custom Insulation Possibilities

Custom electrical insulation development addresses diverse application requirements across multiple industries. Solutions span from precision battery cell insulation in consumer electronics to robust high-voltage systems in industrial power generation. Each application category presents unique engineering challenges requiring specialized material knowledge and design expertise.

The common thread connecting these varied applications is the engineering approach: thorough requirements understanding, thoughtful material selection, rigorous testing and validation, and careful production implementation. This methodology applies whether developing thermal management solutions, optimizing dielectric systems, or engineering mechanical protection.

Integrated Expertise: Where Engineering Meets Manufacturing Excellence

Developing optimal custom electrical insulation requires integrated capabilities rarely found in single organizations. Material expertise without testing facilities produces untested theories. Testing capabilities without manufacturing services creates designs that cannot be produced economically. Manufacturing excellence without engineering support yields components that may not address actual application needs.

Electrolock’s 65 years of experience across battery insulation, high-voltage systems, thermal management, and specialty configurations provides the comprehensive foundation for successful custom development. From initial consultation through production implementation, this integrated approach delivers solutions optimized for both performance and manufacturability.

Begin your custom electrical insulation development with engineering partners who understand that optimal solutions require more than just good materials — they demand extensive capabilities, rigorous methodology, and collaborative partnership.

In today’s high-performance industries — ranging from aerospace and power generation to electric vehicles — electrical systems operate under extreme conditions that push materials to their absolute limits. Electrical wire insulation serves as the first line of defense, protecting conductors from intense heat, mechanical stress, and potentially catastrophic electrical shorts. But not all insulation is created equal, and the difference between adequate and exceptional protection can determine the success or failure of entire operations.

Since 1957, Electrolock has been building success from the inside out, understanding that what you can’t see often makes all the difference in system reliability. Off-the-shelf insulation solutions can fall dangerously short in demanding environments, leaving critical equipment and personnel at risk of costly failures, extended downtime, and safety hazards. Electrolock specializes in custom high-temperature wire and cable insulation designed through advanced materials science to meet these exacting demands, helping customers maximize safety, reliability, and performance simultaneously.

Custom Solutions for Your Specific Applications: Reach out to the Electrolock team today to begin discussing your next electrical insulation project.

Why Electrical Wire Insulation Performance Matters Beyond Basic Protection

Insulation isn’t just a protective coating — it’s a critical component that ensures the integrity of electrical systems while actively contributing to overall performance optimization. It prevents catastrophic turn-to-turn shorts, maintains essential dielectric strength under extreme voltage stress, and shields conductors from environmental and mechanical stresses that can compromise entire systems.

In high-temperature or high-voltage applications, standard insulation materials may degrade rapidly, leading to reduced performance, costly equipment damage, or even catastrophic failure. The real consequences include expensive downtime, major repair costs, potential safety hazards, and the risk of regulatory non-compliance. These risks highlight the critical importance of choosing insulation that is precisely engineered for the specific demands of the operating environment rather than accepting generic solutions.

The Performance Limitations of Standard Insulation Solutions

While conventional insulation products may suffice in routine applications, extreme environments demand materials that can actively enhance system performance rather than merely provide basic protection. Standard materials often succumb to thermal stress, mechanical wear, or chemical exposure, causing premature aging, performance degradation, or complete system failure.

Through advanced materials science, custom solutions utilizing premium materials — like engineered mica tape with superior thermal conductivity, high-strength fiberglass composites, and cut-through resistant Kevlar laminates — offer exceptional performance advantages. These materials provide superior thermal management that enables higher current densities, mechanical strength that withstands extreme operating stresses, and thermal endurance that maintains properties at high temperatures.

Custom solutions ensure insulation performs reliably under these challenging conditions while optimizing system performance parameters that standard materials cannot achieve.

Electrolock’s Engineered High-Temp Wire and Cable Solutions

Electrolock’s High Temp Wire and Cable solutions represent decades of materials engineering expertise applied to applications where safety and performance are absolutely non-negotiable. These solutions are precisely designed to handle Class F and Class H operating temperatures while enduring the intense mechanical and thermal stresses of high-performance machinery.

Using advanced materials, Electrolock creates insulation constructions that exceed exacting specifications. Each design is tailored through comprehensive materials science analysis to the customer’s specific equipment and operating environment, ensuring the insulation maintains its protective and performance-enhancing properties throughout the entire system lifecycle.

Critical applications include aerospace engines where weight and thermal management are paramount, power generation turbines requiring maximum reliability, EV drivetrains demanding compact high-performance solutions, and high-voltage generators where failure is not acceptable. By designing insulation to precise requirements through advanced materials engineering, Electrolock helps extend equipment life, reduce maintenance costs, and prevent unplanned downtime while optimizing system performance.

Explore the Benefits of Custom Electrical Wire Insulation

Custom electrical wire insulation engineered through materials science delivers measurable value across multiple dimensions:

Safety Enhancement: Dramatically reduces the risk of electrical shorts, arc flash incidents, and equipment failure through materials specifically selected for application-specific stress profiles.

Performance Optimization: Maintains superior tensile strength, dielectric properties, and thermal resistance under extreme conditions while enabling higher current densities and improved thermal management.

Regulatory Compliance: Meets stringent industry and safety standards, including UL certifications, providing essential peace of mind for operators and engineers managing critical systems.

Operational Efficiency: Minimizes costly equipment downtime and reduces maintenance requirements, keeping operations running smoothly while extending equipment service life.

By working closely with customers to match insulation materials and engineered designs to specific operating environments, Electrolock ensures that each solution strikes the optimal balance between durability, flexibility, thermal protection, and performance enhancement.

Electrolock: Custom Solutions With Uncommon Expertise

Electrical wire insulation represents far more than a simple component — it’s a critical safeguard for people, equipment, and performance that can actively optimize system capabilities when properly engineered. Electrolock’s custom high-temperature solutions go beyond standard materials, delivering tailored protection and performance enhancement exactly where it’s needed most.

For industries that demand unwavering reliability under extreme conditions, partnering with Electrolock ensures insulation solutions that protect, perform, and endure through the most challenging operating environments.

Contact Electrolock today to explore custom wire and cable insulation solutions designed through advanced materials science for your specific application requirements.

In large generators and high-voltage stator coils, insulation is constantly under pressure — literally. These systems endure immense mechanical stress, high operating temperatures, and the constant risk of catastrophic electrical shorts that can result in costly generator failures and extended downtime. At critical points, like the crossover areas in Roebel bars where conductors transition positions, insulation materials have to do more than just resist heat — they must stand up to intense puncture forces, shear stress, and long-term mechanical wear. That’s where advanced Kevlar® insulation products excel.

Since 1957, Electrolock has been building success from the inside out, understanding that what you can’t see often makes all the difference in system reliability. Our Keveloc® and Kevenex® offerings represent this commitment to engineering excellence — specialized solutions engineered specifically to enhance durability and cut-through resistance in the most demanding applications. By combining the exceptional strength properties of Kevlar with Electrolock’s decades of insulation expertise, these precision-engineered laminates offer protection exactly where it matters most.

Custom Solutions for Your Specific Applications: Reach out to the Electrolock team today to begin discussing your next electrical insulation project.

Why Kevlar for Critical Electrical Insulation Applications?

Kevlar is renowned for its role in protective gear and high-strength composites, but its unique properties are equally valuable in electrical insulation applications where failure is prohibitively expensive. With exceptional tensile strength and superior resistance to puncture, Kevlar laminates act as a reliable barrier against turn-to-turn shorts, particularly at crossover points where conductors overlap and mechanical stress concentrates to levels that can compromise standard insulation materials.

In the precision manufacturing process of VPI stator coils and bars, these barrier inserts are strategically applied during pre-consolidation phases, ensuring long-term circuit integrity and dramatically reducing the risk of costly downtime or equipment failure that can cascade into major operational disruptions.

Keveloc: Engineered for Maximum Strength and Uncompromising Reliability

Keveloc is precision-designed for the most demanding applications, where insulation faces extreme compression and shear forces that would destroy conventional materials. With impressive technical specifications including a tensile strength of 175 pounds per inch width and an exceptional shear puncture rating of 1,381 pounds, Keveloc provides a formidable barrier that resists cut-through even in the most punishing operating conditions.

At just 0.015 inches thick, it adds robust mechanical protection without compromising coil design constraints or electromagnetic performance. Engineered for Class F or Class H machines with thermal ratings that can handle operating temperatures up to 180°C, Kevoloc proves ideal for crossover barriers in Roebel conductors and other high-voltage applications where thermal and mechanical stresses combine. For operators managing critical power generation assets, this translates to dependable durability and proven protection against turn-to-turn shorts precisely where failure is most likely to occur and cause maximum damage.

Kevenex: Flexible Engineering and Customizable Protection Solutions

Kevenex delivers many of the same advanced protective benefits as Kevoloc, but is specifically optimized for Class F machine applications where thermal requirements and operating conditions demand tailored solutions. It provides reliable puncture resistance under compression and shear stress, making it exceptionally well-suited for use as a crossover barrier in VPI stator coils and bars during critical pre-consolidation manufacturing phases.

One of Kevenex’s key engineering advantages is its exceptional customization flexibility. It can be manufactured to customer-specified widths, lengths, or complex shapes, ensuring seamless integration into unique coil designs and geometric requirements. This precision customization capability allows engineers to adapt insulation solutions to their exact specifications without compromising protective performance or manufacturing efficiency.

Stronger Together: Strategic Use of Kevoloc and Kevenex in Combination

While both materials demonstrate exceptional performance independently, Electrolock’s engineering expertise often recommends using them together to provide comprehensive layered protection across different stress points within the same system. By strategically combining Kevoloc’s superior tensile and puncture resistance with Kevenex’s adaptable design capabilities, insulation systems gain added assurance against mechanical wear and electrical failure modes.

This engineered approach reflects our deep understanding of how different areas within high-voltage systems experience varying stress profiles. The result is dramatically improved long-term reliability, reduced maintenance requirements, and extended equipment service life — all of which translate into substantial cost savings and fewer unplanned outages for operators managing critical power infrastructure.

Optimize Kevlar Insulation With Advanced Materials Engineering

When it comes to protecting high-voltage coils and bars in mission-critical applications, standard insulation simply isn’t sufficient for the demands of modern power generation. Kevlar-based solutions like Kevoloc and Kevenex provide the essential cut-through resistance, thermal stability, and mechanical durability needed to withstand punishing mechanical and electrical stresses that define today’s high-performance electrical systems.

Electrolock continues to lead in developing specialized insulation solutions for demanding applications, leveraging our extensive materials engineering expertise to help customers maintain peak performance and uncompromising reliability where failure is not an option. Our commitment to building success from the inside out means understanding the critical details that make the difference between reliable operation and costly failures.

Contact Electrolock today to discuss how Kevoloc and Kevenex can be precisely tailored to meet your specific insulation requirements and enhance the durability of your high-voltage systems.

Designing cables that can withstand extreme temperatures and maintain circuit integrity is a critical challenge for engineers working at the frontiers of technology. Traditional extruded plastics or rubber insulation often fail catastrophically when exposed to high heat, fire, or mechanical stress, leaving critical systems vulnerable at precisely the moment they’re needed most. For applications requiring insulation at temperatures up to 1000℃, a more robust solution is necessary. Premium mica cable tape offers a proven way to meet these demanding requirements, delivering superior thermal performance, fire resistance, and long-term reliability that engineers can trust.

Custom Solutions for Your Specific Applications: Reach out to the Electrolock team today to begin discussing your next electrical insulation project.

The Critical Challenges of High-Temperature Cable Design

High-temperature cable applications span a wide range of industries where failure is not an option — from appliance manufacturing and industrial furnaces to aerospace and military shipboard systems. In these unforgiving environments, conventional insulation materials quickly reach their thermal limits, risking circuit failure or degradation that can compromise entire operations. Engineers also face increasingly stringent fire safety requirements, including low smoke and halogen-free standards, especially in enclosed or critical environments where every second of circuit integrity matters. Maintaining reliable performance under these extreme conditions — often for extended periods — is essential for safety, compliance, and operational continuity.

How Premium Mica Cable Tape Solves These Mission-Critical Challenges

Premium mica cable tape provides a unique combination of heat resistance and mechanical stability that other materials simply cannot match. Since 1957, Electrolock has been engineering solutions that build success from the inside out, and our Pyrodox® line of mica tapes exemplifies this commitment to excellence.

These advanced materials feature thin inorganic mica paper bonded with high-temperature silicone resins to a reinforcing backing (typically glass). This design allows the tape to be precision-slit to widths of less than 0.1 inches and spiral-wrapped around wires as small as 22 gauge, delivering uniform insulation even on fine-gauge conductors where precision matters most.

Pyrodox mica tapes have been widely adopted in applications requiring UL-certified high-temperature performance that engineers depend on. They are successfully used in UL 5107, UL 5128, and UL 2196 cables for furnaces, thermocouples, appliance wiring, and igniter cables. In military shipboard applications, Pyrodox provides low-smoke, halogen-free insulation that maintains circuit integrity under fire and heat stress when lives could be on the line. The tape’s inorganic mica composition ensures it does not burn, degrade, or release toxic fumes, offering unmatched fire survival capabilities that provide critical evacuation time.

Engineered Variants and Manufacturing Advantages That Drive Efficiency

The Pyrodox family includes several styles, each precisely tailored to specific application requirements. These different offerings vary in thickness, mica content, and weight, allowing engineers to select exactly the right tape for their temperature, voltage, and mechanical specifications. One specialized variant, Pyrodox GX, uses premium mica with a halogen-free silicone binder and non-alkaline fiberglass backing. Pyrodox GX is engineered to endure extreme electrical and thermal overloads while tolerating high-moisture environments, making it ideal for cables requiring extended fire survival time. And due to its premium mica composition, it performs alternatives that rely on standard phlogopite and muscovite micas.

Pyrodox tapes are supplied in slit pads or traverse-wound spools, offering long continuous lengths without bulky tape splices that can compromise performance. This thoughtful design minimizes taping machine downtime and ensures consistent wall thickness along the cable, helping manufacturers maintain high-quality production standards while reducing operational inefficiencies that impact the bottom line.

Industry Validation and Proven Reliability Where It Matters Most

Lay flat tubing excels in automated manufacturing environments. The flattened storage configuration reduces shipping costs and simplifies handling systems. When expanded during installation, the tubing provides complete encapsulation with minimal operator intervention. This characteristic makes lay-flat solutions particularly attractive for high-volume production scenarios where labor efficiency impacts overall costs.

Spiral wound tubing requires more consideration during installation planning. However, this investment in setup complexity pays dividends through enhanced customization options. Electrolock’s spiral wound solutions can be supplied with specialized features, including notched cuts, sealed end caps, and custom dimensions that integrate seamlessly into specific manufacturing processes.

Customization Capabilities and Industrial Insulation Solutions

Pyrodox mica cable tapes have earned a reputation for unwavering reliability and performance across multiple industries where failure is not acceptable. Notably, Pyrodox is the only tape that consistently passes UL 2196 testing requirements for fire survival cables, providing engineers with the confidence they need in their protective capabilities. From oil exploration’s harsh downhole conditions and aerospace’s thermal extremes to defense applications, mass transit systems, and high-temperature industrial processes, Pyrodox delivers proven circuit integrity and thermal protection precisely where it matters most.

Building Success from the Inside Out With Electrolock

For engineers and cable manufacturers facing extreme thermal, mechanical, and fire-resistant requirements, mica cable tape represents more than just a component — it’s a critical solution that enables innovation in the most demanding applications. Electrolock’s Pyrodox line offers unmatched high-temperature performance, manufacturing efficiency, and reliability forged through decades of materials engineering expertise, ensuring that cables maintain circuit integrity even in the most unforgiving environments.

By selecting the right Pyrodox variant for their specific application, engineers can achieve long-term durability, UL compliance, and the peace of mind that comes from partnering with a company that has been building success from the inside out since 1957.

Contact Electrolock today to discuss how our premium mica cable tape solutions can enhance the reliability of your high-temperature cable applications.

As electric vehicle adoption accelerates, ensuring robust thermal propagation protection in EV battery systems has become increasingly critical. When thermal runaway occurs — a rapid, uncontrollable temperature increase in battery cells — effective thermal propagation protection solutions can provide crucial evacuation time and prevent catastrophic cell-to-cell failure propagation. Understanding the performance characteristics of different protection materials helps procurement teams make informed decisions for their specific EV battery applications.

Custom Solutions for Your Specific Applications: Reach out to the Electrolock team today to begin discussing your next electrical insulation project.

Understanding Thermal Runaway and Protection Requirements

Thermal runaway represents a significant safety challenge in lithium-ion battery systems, where individual cell failures can cascade throughout entire battery packs. While Electrolock’s solutions focus on mitigating thermal runaway impact and providing critical evacuation time rather than preventing its initial occurrence, the selection of appropriate thermal propagation protection materials directly influences overall system safety.

Current safety regulations, including UN GTR No. 20 and the NHTSA’s Battery Safety Initiative, establish minimum requirements for thermal propagation protection, typically mandating a period of safe evacuation time when thermal events occur.

Three Primary Material Approaches for EV Battery Protection

Mica-Based Thermal Barriers

Mica remains the industry standard for high-performance thermal propagation protection in EV applications. Its natural crystalline structure provides exceptional thermal stability and flame resistance capabilities that prove essential when battery temperatures exceed critical thresholds.

Performance Characteristics:

• Exceptional high-temperature stability, maintaining integrity at extreme temperatures
• Superior flame retardancy with UL 94 V-0 rating
• Low thermal conductivity prevents heat transfer between cells
• Excellent dielectric properties provide electrical isolation
• Design flexibility available in rigid, flexible, and tape configurations

Application Diversity: Mica-based solutions excel across multiple battery pack protection levels, from cell-to-cell barriers to module-level insulation and pack perimeter protection. The material’s adaptability enables engineers to implement comprehensive thermal management strategies throughout battery assemblies.

Cost Considerations: Among thermal runaway barrier materials, mica offers the most cost-effective solution while maintaining superior performance characteristics, making it particularly attractive for large-scale EV production applications.

Ceramic Insulation Solutions

Ceramic materials provide exceptional performance in extreme temperature environments where maximum thermal protection is required. These solutions excel in high-stress applications where preventing thermal runaway propagation is paramount.

Performance Characteristics:

• Outstanding thermal shock resistance under rapid temperature changes
• Exceptional dimensional stability, maintaining protective geometry during thermal events
• Superior chemical resistance against battery electrolytes and decomposition products
• High mechanical strength withstands physical stresses during battery operation

Application Diversity: Ceramic solutions prove particularly valuable in commercial EV applications and high-performance battery systems where enhanced protection justifies additional material investment. These materials work effectively in both rigid barrier applications and specialized thermal management configurations.

Cost Considerations: While ceramic materials require a higher initial investment compared to other options, their exceptional durability and protection capabilities often justify the cost in mission-critical applications where battery failure consequences are severe.

PET-Based Protection Systems

PET insulation materials offer balanced performance for EV applications requiring reliable thermal protection with manufacturing efficiency considerations. These solutions provide effective thermal propagation barriers while maintaining compatibility with automated production processes.

Performance Characteristics:

• Good thermal resistance suitable for moderate temperature applications
• Excellent mechanical durability, resisting manufacturing and handling stresses
• Chemical compatibility with battery components and assembly processes
• Lightweight characteristics supporting overall vehicle efficiency goals

Application Diversity: PET solutions work effectively in passenger EV applications where standard thermal protection requirements align with material capabilities. These materials integrate well with multi-layered insulation systems and can be combined with other materials for enhanced protection.

Cost Considerations: PET-based solutions typically offer the most economical option for applications where moderate thermal protection meets safety requirements, making them attractive for high-volume consumer EV production.

Multi-Layered System Approaches

Beyond individual material solutions, multi-layered thermal insulation systems combine different materials to achieve optimized performance across various protection levels. These engineered systems enable customized thermal management strategies addressing specific battery pack configurations and performance requirements.

Multi-layered approaches typically integrate primary thermal barriers with secondary protection elements, creating redundant safety systems that maintain protection even when individual components experience degradation during thermal events.

Protection Implementation Across Battery Levels

Cell-to-Cell Protection

Individual cell protection requires materials capable of containing thermal events at the source while maintaining compact dimensions. Solutions must balance thermal protection with space efficiency to maximize battery energy density.

Module-Level Barriers

Module-level protection focuses on preventing thermal propagation between battery modules while accommodating various module configurations and cooling system requirements. Materials must provide reliable performance across different module designs and sizes.

Pack-Level Insulation

Pack-level protection systems, including Electrolock’s Go-Therm Thermal Runaway Barrier, provide comprehensive thermal management for complete battery assemblies. These solutions focus on occupant protection and system-level thermal control.

Engineering the Right Thermal Propagation Protection Solution

Selecting optimal thermal propagation protection requires careful evaluation of multiple factors, including battery chemistry compatibility, thermal performance requirements, manufacturing constraints, and long-term reliability needs. Each EV application presents unique challenges requiring customized material selection and system design.

Electrolock’s comprehensive thermal insulation expertise enables detailed application analysis and custom solution development tailored to specific EV battery requirements. Our engineering approach considers both standard and custom configurations to optimize thermal protection while meeting manufacturing and cost objectives.

Working with experienced thermal insulation specialists ensures that protection solutions address both immediate safety requirements and long-term performance demands across various EV operating conditions.

Contact Electrolock today to discuss how our thermal propagation protection solutions can enhance the safety and reliability of your EV battery systems.

Medium and high-voltage motor applications demand precise insulation solutions that balance electrical protection, thermal management, and mechanical durability. When evaluating insulation sleeving versus spiral wound tubing for motor systems, procurement professionals must consider how each solution addresses the unique challenges of stator windings, lead connections, and crossover insulation. Understanding these performance differences ensures optimal motor reliability while meeting evolving industry efficiency standards.

Custom Solutions for Your Specific Applications: Reach out to the Electrolock team today to begin discussing your next electrical insulation project.

Motor Insulation Requirements Drive Material Selection

Modern motor coil insulation systems must simultaneously provide dielectric protection, manage thermal loads, and maintain mechanical integrity under demanding operational conditions. In medium and high-voltage applications, these requirements intensify significantly, particularly as industry trends toward more compact motor designs and stricter efficiency regulations under standards like IEEE 112-2017 continue driving innovation.

The selection between insulation sleeving and spiral wound solutions depends largely on specific motor components and their operational demands within the complete insulation system.

Understanding Solution Differences in Motor Context

Insulation Sleeving in Motor Applications

Traditional insulation sleeving, while effective in battery applications, faces limitations when adapted for motor environments. These solutions typically provide basic dielectric protection around individual conductors but lack the comprehensive performance characteristics required for demanding motor applications.

Standard sleeving approaches work adequately for lower-stress applications but may not address the complex thermal cycling, mechanical vibration, and electrical stress concentrations common in medium and high-voltage motor systems.

Spiral Wound Tubing for Motor Performance

Spiral wound tubing construction offers distinct advantages in motor applications through its multi-layer design approach. This construction method enables the integration of specialized materials — such as mica papers, aramid reinforcements, and polyester films — within a single protective structure tailored specifically for motor operating conditions.

The overlapping spiral construction provides enhanced mechanical durability against the vibration and thermal cycling inherent in motor operations, while enabling precise customization of electrical and thermal properties.

Component-Specific Performance Analysis

Stator Winding Protection

In form-wound stator coil applications, spiral-wound solutions demonstrate clear advantages. The ability to incorporate mica-based materials within the spiral construction provides the high-temperature stability and partial discharge resistance essential for reliable stator performance.

Spiral wound tubing can accommodate the precise wall thickness requirements needed to optimize copper fill factors while maintaining required dielectric strength — a critical consideration for maximizing power output in space-constrained motor designs.

Lead Connection Insulation

Motor lead connections experience unique stress concentrations where conductors transition between different voltage potentials. Spiral wound tubing’s customizable construction enables the integration of gradient control materials and enhanced mechanical protection specifically designed for these critical transition zones.

The multi-layer approach allows for tailored electrical stress distribution, reducing the risk of premature failure at connection points where standard sleeving solutions may prove inadequate.

Crossover Insulation Requirements

In multi-turn motor configurations, crossover regions demand specialized protection against both electrical and mechanical stress. Spiral wound solutions excel here through their ability to maintain insulation integrity in geometrically complex areas while providing the mechanical support necessary during thermal cycling operations.

The engineered construction enables consistent performance across varying conductor positions and orientations — a significant advantage over conventional sleeving approaches that may not conform reliably to complex geometries.

Thermal and Electrical Performance in Motor Environments

Managing Motor Operating Temperatures

Motor applications typically operate at higher continuous temperatures than many other electrical systems. Advanced motor coil insulation requires materials capable of sustained performance at elevated temperatures while maintaining dimensional stability.

Spiral wound construction enables the selection and positioning of temperature-resistant materials like polyimide or aramid papers in critical thermal zones, while incorporating thermal management features that standard sleeving cannot provide.

Electrical Stress Distribution

High-voltage motor applications create significant electrical stress concentrations, particularly at insulation terminations and geometric discontinuities. Spiral wound tubing’s layered construction allows for engineered stress control through the strategic placement of semi-conductive materials and gradient control elements.

This engineered approach to stress management proves particularly valuable in applications operating above NEMA MG-1 standards, where conventional insulation approaches may not provide adequate protection against partial discharge activity.

Manufacturing and Maintenance Considerations

New Motor Manufacturing

In original equipment manufacturing, spiral wound tubing integrates effectively with automated coil forming processes. The customizable nature enables manufacturers to specify precise dimensional and performance characteristics that optimize both manufacturing efficiency and long-term reliability.

The ability to incorporate multiple functional materials within a single component reduces inventory complexity while ensuring consistent quality across production runs.

Motor Rewinding and Repair Applications

Motor rewinding scenarios often require insulation replacement in existing motor geometries where space constraints limit material options. Spiral wound solutions provide the flexibility needed to match original specifications while potentially upgrading performance characteristics.

The engineered construction approach enables repair technicians to address specific failure modes — such as inadequate thermal management or insufficient electrical protection — through targeted material selection within the spiral wound structure.

Selecting the Right Insulation Sleeving Solution for Motors

When evaluating these options for motor applications, several factors guide optimal selection:

Consider spiral wound tubing when:

• Applications involve medium to high-voltage motor systems
• Thermal management requirements exceed standard capabilities
• Complex geometries demand engineered stress control
• Long-term reliability in demanding environments justifies investment
• Customization needs require multiple material properties

Standard sleeving may suffice when:

• Systems require lower voltage applications with minimal thermal stress
• Budget constraints prioritize basic protection over enhanced performance
• Simple geometries don’t require specialized engineering

However, in most medium and high-voltage motor applications, spiral wound solutions provide the comprehensive protection and performance optimization that motor reliability demands.

Electrolock’s Engineering Expertise Drives Optimal Results

Every motor application presents unique requirements that standard catalog solutions may not address effectively. Electrolock’s comprehensive engineering capabilities include detailed application analysis, custom material selection, and validation testing to ensure optimal performance under specific operating conditions.

Our experience with motor and generator insulation systems enables informed guidance through the selection process, whether for new manufacturing or rewinding applications requiring upgraded performance.

Contact Electrolock today to discuss how our engineered insulation solutions can enhance the reliability and performance of your motor applications.

When selecting industrial insulation solutions for electrical applications, procurement professionals often face a choice between lay flat tubing and spiral wound tubing. Both options provide reliable protection for wires, cables, and battery components, but each offers distinct advantages depending on your specific application requirements. Understanding these differences helps ensure optimal performance while managing costs effectively.

Custom Solutions for Your Specific Applications: Reach out to the Electrolock team today to begin discussing your next electrical insulation project.

Understanding the Fundamental Differences

Lay flat tubing represents a flexible, thin-walled solution that stores flat when not in use, offering advantages in storage efficiency and automated manufacturing systems. The flattened configuration allows for efficient processing in high-volume production environments, making it particularly valuable for applications requiring streamlined installation processes.

Spiral wound tubing, conversely, provides a more robust construction method where materials are wound in overlapping layers to create customizable wall thicknesses and performance characteristics. This construction approach enables engineers to precisely tailor insulation properties to meet specific application demands.

Application Suitability: Where Each Solution Excels

Battery and Electronics Applications

For battery insulation applications, lay flat tubing proves particularly effective in providing jelly roll insulation and tab protection. The thin-wall capability and space-efficient design maximize energy density in constrained battery packs. PET-based lay flat solutions like Electrolock’s 740 HS deliver excellent dielectric protection while maintaining compatibility with automated manufacturing processes.

However, spiral wound tubing offers superior versatility when applications require specific performance combinations. The ability to incorporate multiple materials — such as aramid, polyimide, or specialized barrier films — into a single tube structure provides enhanced protection against multiple threats simultaneously.

Industrial and Power Generation Uses

In demanding industrial environments, spiral wound construction demonstrates clear advantages. The multi-layer approach enables the integration of materials with complementary properties: outer layers might provide chemical resistance while inner layers focus on dielectric strength. This flexibility proves particularly valuable in high-voltage applications where complex performance requirements demand engineered solutions.

Lay flat tubing, while effective for standard protection needs, typically serves better in applications where simplicity and cost-effectiveness take precedence over multi-faceted performance requirements.

Installation and Manufacturing Considerations

Production Line Integration

Lay flat tubing excels in automated manufacturing environments. The flattened storage configuration reduces shipping costs and simplifies handling systems. When expanded during installation, the tubing provides complete encapsulation with minimal operator intervention. This characteristic makes lay-flat solutions particularly attractive for high-volume production scenarios where labor efficiency impacts overall costs.

Spiral wound tubing requires more consideration during installation planning. However, this investment in setup complexity pays dividends through enhanced customization options. Electrolock’s spiral wound solutions can be supplied with specialized features, including notched cuts, sealed end caps, and custom dimensions that integrate seamlessly into specific manufacturing processes.

Customization Capabilities and Industrial Insulation Solutions

Material Flexibility

Both tubing types accommodate various materials, but spiral wound construction offers broader customization potential. While lay flat tubing typically utilizes PET or PVC formulations, spiral wound systems can incorporate diverse material combinations, including Nomex®, Kapton®, fiberglass, and specialized barrier films within a single tube structure.

This flexibility enables spiral wound solutions to address complex application requirements — such as simultaneous electrical insulation, thermal management, and chemical resistance — that might otherwise require multiple separate components.

Dimensional Options

Lay flat tubing provides excellent options for thin-wall applications, with capabilities as low as 0.002″ wall thickness. This characteristic proves valuable when space constraints demand minimal insulation bulk while maintaining electrical protection.

Spiral wound construction offers broader dimensional flexibility, accommodating wall thicknesses from 0.002″ to 0.125″ and inside diameters ranging from 0.050″ to 6.0″. This range enables precise matching to specific application requirements while maintaining the structural integrity that multi-layer construction provides.

Making the Right Choice for Your Application

When evaluating these industrial insulation solutions, consider your primary requirements:

Choose lay flat tubing when:

• Cost-effectiveness takes priority
• Applications involve high-volume, automated assembly
• Space constraints demand minimal wall thickness
• Standard electrical insulation requirements are sufficient

Select spiral wound tubing when:

• Applications demand multiple performance characteristics
• Custom material combinations provide value
• Installation flexibility justifies additional complexity
• Long-term reliability in demanding environments is critical

The Right Industrial Insulation Solutions Require Engineering Support

Regardless of which solution better fits your initial requirements, working with experienced insulation specialists ensures optimal results. Electrolock’s comprehensive engineering support includes material selection guidance, custom sizing specifications, and validation testing to ensure performance reliability throughout your product’s lifecycle.

Contact Electrolock today to discuss how our engineered tubing solutions — whether lay flat or spiral wound — can enhance the reliability and efficiency of your industrial insulation applications.

Engineers evaluating manufacturing methods for electrical insulation components need to understand when rotary die cutting provides both technical and economic advantages. This high-volume process uses circular steel tools to punch precise shapes while simultaneously laminating materials with adhesive layers, making it ideal for applications requiring consistent quality and material consolidation.

Custom Solutions for Your Manufacturing Applications: Reach out to the Electrolock team today to begin discussing your next electrical insulation project.

When Rotary Die Cutting Makes Economic Sense

The economic threshold for rotary die cutting begins at volumes over a couple of hundred parts, where the initial tooling investment becomes cost-effective compared to alternative manufacturing methods. While the circular steel tools require higher upfront investment than standard punching dies, the per-part cost advantages become significant at production volumes.

Material consolidation represents a major economic benefit of rotary die cutting. The process can laminate multiple materials with adhesive layers in a single operation, eliminating separate bonding steps and reducing manufacturing time. This consolidation capability is particularly valuable for complex electrical insulation assemblies requiring precise material positioning and consistent bond strength.

Compared to laser cutting, rotary die cutting offers substantial advantages for production volumes. Laser cutting, while more precise for prototyping and smaller runs, becomes prohibitively expensive and slow for high-volume manufacturing. The speed and consistency of rotary die cutting make it the preferred choice when production volumes justify the tooling investment.

Critical Technical Advantages for Electrical Applications

The most significant technical advantage of rotary die cutting for electrical applications is the production of non-carbonized edges. Unlike laser cutting, which can create carbonized edges that may affect electrical properties, rotary die cutting produces clean, non-carbonized cuts essential for maintaining insulation integrity in electrical components.

Tolerance capabilities of rotary die cutting typically achieve precision within a few thousandths of an inch, meeting the demanding requirements of electrical insulation applications. This precision, combined with the process’s ability to handle various substrates, including films, papers, and non-wovens, makes it suitable for complex electrical insulation geometries.

Multi-layer material handling capabilities enable engineers to create complex insulation assemblies in a single operation. The process can integrate different material properties — such as dielectric strength, thermal resistance, and mechanical durability — into cohesive assemblies with consistent performance characteristics.

Material and Adhesive Selection Guidelines

Adhesive selection becomes critical when designing for rotary die cutting, as the process must accommodate the specific bonding requirements between different substrate materials. Engineers must consider adhesive compatibility with materials like steel, aluminum, and various insulation films to ensure proper bond strength and peel strength performance.

Material thickness ranges vary depending on the specific substrates and adhesive systems involved. The process accommodates various combinations of films, papers, and non-wovens, but engineers should consult with manufacturing specialists to optimize material selection for their specific applications. Chemical compatibility becomes particularly important when selecting adhesives that will maintain performance throughout the component’s service life.

Substrate material properties directly influence adhesive selection criteria. Different base materials — whether metallic, polymeric, or composite — require specific adhesive chemistries to achieve optimal bonding performance. Understanding these relationships ensures long-term reliability of the finished insulation components.

Design Guidelines and Quality Control

Geometry optimization plays a crucial role in rotary die cutting success. Engineers should design parts that maximize material utilization while minimizing waste, considering the circular motion of the cutting tool and the continuous nature of the process. Simple geometry modifications can significantly improve manufacturability and reduce material costs.

Quality control methodology relies heavily on optical comparators for precision measurement and validation. These instruments enable accurate measurement of critical dimensions, ensuring that finished parts meet the tight tolerances required for electrical insulation applications. Regular optical comparator verification helps maintain consistent quality throughout production runs.

Tooling design significantly impacts both part quality and manufacturing efficiency. Working with experienced manufacturers helps optimize tool geometry for specific applications, balancing cutting performance with tool longevity. Proper tooling design also minimizes material stress during cutting, preserving the electrical properties of sensitive insulation materials.

Application-Specific Considerations for Electrical Components

High-voltage insulation applications require particular attention to edge quality and dimensional precision. The non-carbonized edges produced by rotary die cutting help maintain dielectric integrity, while the process’s tolerance capabilities ensure consistent electrical performance across production runs.

Battery applications demand exceptional cleanliness standards that rotary die cutting can accommodate through proper process controls. The ability to create complex shapes with integrated adhesive layers makes this process particularly suitable for battery insulation components requiring precise fit and consistent performance.

Thermal barrier applications benefit from the process’s ability to maintain material properties through the cutting operation. Unlike thermal cutting methods that may alter material characteristics, mechanical cutting preserves the thermal performance of specialized insulation materials.

Maximizing Manufacturing Success With Electrolock

Successful rotary die cutting for electrical insulation requires understanding the intersection of volume economics, technical requirements, and material capabilities. Engineers should evaluate their specific volume requirements against the process’s economic threshold while considering the technical advantages of non-carbonized edges and material consolidation capabilities.

Contact Electrolock today to discuss how rotary die cutting can optimize your electrical insulation manufacturing requirements while delivering the precision and consistency your applications demand.

Electric vehicle motors operate under demanding conditions that make custom motor slot insulation solutions the industry standard rather than a premium option. Unlike industrial motors, where standard solutions might suffice, EV applications require precisely engineered insulation that maximizes power density while meeting stringent automotive performance and durability requirements.

Below, we explore the reasons why motor slot insulation for EVs demands a customized approach, and how Electrolock is positioned to deliver the engineered solutions this space demands.

Custom Solutions for Your EV Applications: Reach out to the Electrolock team today to begin discussing your next electrical insulation project.

EV Motor Slot Insulation Challenges Drive Custom Solutions

EV motors face unique challenges that standard insulation solutions simply cannot address effectively. Space optimization is critical — thinner insulation allows for more copper conductor in the slot, directly translating to higher power output. This space-performance relationship is fundamental to EV motor design, where every millimeter of saved insulation thickness can significantly impact motor power density.

Thermal management presents another significant challenge. EV motors run hot due to their compact, high-performance nature. While thermally conductive insulation materials would help motors operate more efficiently, current material technology limits these options. The industry continues to push for the thinnest possible insulation that can still maintain thermal performance requirements.

Chemical compatibility adds complexity that industrial motors rarely encounter. EV slot insulation must withstand exposure to automotive transmission fluids (ATFs) and other automotive chemicals throughout the motor’s operational life. This compatibility requirement extends to adhesive systems, which must maintain their bonding properties when exposed to these automotive fluids.

Long-term durability requirements are particularly stringent for EV applications. Motors must perform reliably for a decade or more, making material selection and construction design critical for sustained performance under automotive conditions. After all, the insulation solution should match the expected life of the motor itself.

Custom Material Construction Optimization for EV Performance

Achieving optimal EV motor slot insulation requires sophisticated multi-layer laminate constructions that balance multiple competing performance requirements. Engineers must optimize these constructions to simultaneously address thermal conductivity, dielectric strength, mechanical properties, and chemical compatibility within the thinnest possible profile.

The construction process involves going as thin as possible from a thickness perspective while still meeting all electrical and mechanical specifications. This optimization challenge requires careful material selection and layering strategies to ensure the final construction maintains dielectric breakdown resistance and partial discharge performance.

Advanced laminate designs enable manufacturers to fine-tune properties for specific EV applications. By combining different materials in precise configurations, engineers can create slot insulation that maximizes copper fill factor while maintaining all required performance characteristics. This level of customization is essential because each EV motor design presents unique space constraints and performance requirements.

EV-Specific Performance Requirements

EV motor slot insulation must meet several critical performance criteria that distinguish it from industrial motor applications. Dielectric breakdown and partial discharge resistance are fundamental electrical requirements that ensure safe operation under high-voltage conditions typical in EV motors.

Mechanical properties play an equally important role. Abrasion resistance and cut-through protection are essential during motor manufacturing and throughout the motor’s operational life. The insulation must withstand mechanical stresses during installation while maintaining its protective properties over time.

Chemical compatibility testing validates the insulation’s ability to resist degradation when exposed to automotive fluids. This testing encompasses both the insulation materials and adhesive systems, ensuring comprehensive compatibility with the automotive operating environment.

Thermal cycling durability testing simulates the repeated heating and cooling cycles that EV motors experience during normal operation. The insulation must maintain its electrical and mechanical properties through these thermal stresses to ensure long-term reliability.

The Future of EV Motor Slot Insulation

The automotive industry’s push for higher performance and greater efficiency continues to drive innovation in slot insulation materials and constructions. Emerging materials promise even thinner profiles while maintaining or improving performance characteristics.

Thermal conductivity improvements represent a significant development opportunity. If materials technology can deliver thermally conductive insulation at viable thicknesses, EV motors could achieve better thermal management while maintaining the space optimization benefits of thin insulation profiles.

Custom Solutions: The EV Standard

For EV motor manufacturers, custom motor slot insulation represents the standard approach rather than a specialty option. The unique combination of space constraints, thermal management requirements, chemical compatibility needs, and long-term durability demands makes off-the-shelf solutions inadequate for most EV applications.

At Electrolock, we have decades of experience working through these challenges. Our in-house testing and engineering teams give you the insight and data to find perfect-fit solutions — no matter the constraints of performance and design.

Contact Electrolock today to discuss how our custom slot insulation solutions can optimize your EV motor designs for maximum performance and reliability.

In high voltage electrical systems, the quality of insulation materials used in form-wound stator coils directly impacts system performance, safety, and longevity. As power demands increase and space constraints tighten, engineers face growing challenges in selecting the optimal insulation solutions. Electrolock has been engineering innovative insulation materials since 1957, helping clients navigate these complex requirements with custom-designed solutions.

Today, we’re sharing some of our insights about material selection, testing, and custom solutions as they relate to form-wound stator coils — and the performance of the motors and generators they serve.

Custom Solutions for Your Specific Applications: Reach out to the Electrolock team today to begin discussing your next electrical insulation project.

Understanding Form-Wound Stator Coils vs. Random-Wound Systems

Form-wound coils represent the sophisticated end of the motor and generator spectrum, used primarily in medium to high voltage applications. Unlike random-wound systems that use round wire in low-voltage motors, form-wound coils are precisely shaped and then insulated with specialized materials like mica tape. This configuration allows for higher performance but requires more sophisticated insulation solutions to manage the increased electrical, thermal, and mechanical stresses.

Key Materials in High Voltage Coil Insulation

The foundation of high voltage coil insulation begins with mica — specifically mica paper. This natural mineral is processed through a pulping procedure similar to wood pulping, creating a material with exceptional dielectric properties. The mica paper is then typically laminated to carrier materials such as:

• Polyester film
• Polyester fleece
• Fiberglass

These composite structures combine the electrical isolation properties of mica with the mechanical support of the carrier materials. In most applications, an epoxy binder system provides the final cohesive structure, though silicone binders may be used in specialized high-temperature, compact applications.

How Insulation Directly Affects Power Output

In high voltage coils, the relationship between insulation and power is straightforward but critical: power equals voltage times current. To maximize power in a fixed space, engineers need to optimize for maximum current capacity, which means:

1. Using thinner insulation materials that maintain the required dielectric strength
2. Maximizing copper fill factor in the available space
3. Efficiently managing heat dissipation to prevent performance degradation

Thinner, high-performance insulation systems allow for more copper conductor material within the same dimensional constraints, directly increasing the current-carrying capacity and thus the power output of the system.

The Evolution of Form-Wound Stator Coil Insulation Technologies

Over the past decade, the industry has seen significant shifts in insulation approaches for high voltage coils:

• Movement from multi-layer systems (triplex or four-layer) to more efficient two-ply designs
• Increasing mica content within the same thickness profile (e.g., 160-gram paper instead of 120-gram)
• Development of advanced binder systems with higher glass transition temperatures
• Engineering materials that balance dielectric strength with improved thermal conductivity

These advancements have enabled higher power densities while maintaining or improving reliability — a critical consideration as industries demand more compact, efficient motor and generator systems.

Balancing Competing Performance Requirements

The challenge in coil insulation design lies in balancing competing properties:

• Dielectric Strength vs. Thermal Management: Higher voltage requires better electrical isolation, but this often comes at the expense of thermal conductivity.
• Mechanical Durability vs. Thickness: Thinner materials allow more copper, but may compromise durability during manufacturing and operation.
• Performance vs. Cost: Premium materials offer superior properties but must be justified against economic constraints.

Engineers must carefully consider the specific voltage and thermal requirements of each application when selecting insulation systems. This balancing act becomes particularly challenging in extreme environments like electric vehicle motors, where space constraints, heat management, and reliability requirements are especially demanding.

The Value of Expert Engineering Support for Form-Wound Stator Coils

While insulation materials might appear simple, their application in high voltage coil systems requires significant expertise. Some procurement professionals may view these materials as commodities, focusing primarily on price. However, there are dramatic differences between economy and premium solutions — differences that become apparent when materials tear during shipping or fail prematurely in service.

Working with specialists — like the experts at Electrolock — provides advantages beyond just material supply:

• Access to engineers who understand the complex interplay of electrical, thermal, and mechanical properties
• Support for problem-solving when facing challenges like premature coil failure, poor resin penetration, or thermal management issues
• Testing capabilities to validate custom solutions for specific applications
• Responsive service support throughout the product lifecycle

Achieve Engineering Success from the Inside Out With Electrolock

Proper form-wound stator coil insulation selection is fundamental to achieving optimal power output, efficiency, and reliability in high voltage systems. Electrolock has always taken pride in building success from the inside out — recognizing that although insulation may be hidden from view, it makes all the difference to system performance.

For engineers designing high voltage motors, generators, or other coil-based systems, partnering with insulation specialists who understand both the materials and their application provides significant advantages. From material selection through testing and into production, expert guidance ensures that power, efficiency, and reliability goals are met without compromise.

Contact Electrolock’s team to discuss how optimized form-wound coil insulation solutions can enhance the performance of your high voltage electrical systems.

Creating Bespoke Insulation Solutions is What We Do: Reach out to the Electrolock team today to begin discussing your next electrical insulation project.

The Fundamentals of Modern Coil Insulation

Advanced coil insulation systems must address multiple challenges simultaneously: providing dielectric protection, managing thermal loads, and maintaining mechanical integrity—all while optimizing space utilization within the machine design. The selection of appropriate materials requires careful consideration of both electrical and mechanical properties.

Mica-Based Solutions: The Gold Standard

For high-voltage motors and generators, mica-based insulation systems remain the industry benchmark. These materials offer exceptional advantages:

• Superior dielectric strength, crucial for withstanding high voltage stress
• Extraordinary thermal stability, maintaining performance at temperatures up to 1,000°C
• Excellent partial discharge resistance, preventing premature insulation degradation
• Dimensional stability under thermal cycling conditions

Modern mica ground wall tapes, when properly applied with compatible resin systems, provide a robust foundation for reliable operation even in the most demanding environments.

Advanced Polymer Systems

For specialized applications, high-performance polymers like Nomex® (aramid) and Kapton® (polyimide) deliver targeted benefits:

• Exceptional mechanical strength that resists tearing during manufacturing
• Outstanding thermal endurance for continuous high-temperature operation
• Excellent chemical resistance to oils and coolants
• Reduced thickness for maximizing copper fill factors

Critical Components of a Complete Coil Insulation System

A comprehensive coil insulation system integrates several specialized components working together. By adjusting these eight components, coil insulation systems can be used to optimize many parts of a coil’s performance, from thermal management and voltage endurance to manufacturing considerations.

Let’s look closer at these eight essential building blocks.

Ground Wall Insulation

This primary insulation layer provides fundamental protection between the coil conductors and grounded core components. In high-efficiency designs, optimizing ground wall thickness while maintaining dielectric integrity is essential for maximizing space for active conductors.

Conductive Tapes

In medium and high voltage applications, conductive tapes serve critical functions:

• Providing electromagnetic interference (EMI) shielding
• Creating equipotential surfaces that distribute electrical stress evenly
• Establishing reliable grounding connections while maintaining insulation integrity
• Preventing charge accumulation that could lead to partial discharge activity

These specialized tapes, often incorporating materials like graphite or metal particles, ensure electrical stability throughout the winding system.

Corona Suppression Solutions

In machines operating above 4kV, corona suppression materials prevent partial discharge damage at the interface between insulation and core steel. These materials effectively bleed off electrical stress, extending insulation life and preventing premature failure. Applied in slot sections and end-winding areas, they create a controlled conductive path that prevents voltage stress concentrations.

Gradient Tapes for Voltage Control

Applied at coil terminations, gradient tapes create controlled voltage transitions, preventing surface tracking and discharge activity at critical stress points where insulation systems terminate. These tapes extend beyond corona suppression layers to provide complete stress control.

Crossover Insulation

In multi-turn coil designs, crossover regions where conductors transition between different positions require specialized insulation to:

• Prevent turn-to-turn shorts in these vulnerable areas
• Maintain mechanical support during thermal cycling
• Preserve insulation integrity in areas with complex geometries
• Withstand increased electrical stress at these transition points

Rotor Turn Insulation

Specifically designed for rotating components, rotor turn insulation must:

• Withstand extreme centrifugal forces during high-speed operation
• Maintain inter-turn isolation despite thermal expansion and contraction
• Provide electrical isolation between adjacent conductors
• Resist mechanical degradation from repeated thermal and mechanical cycling

B-Staged Tapes & Blocking Felts

These manufacturing-friendly materials provide dual benefits:

• B-staged (partially cured) tapes allow for conformability during coil forming while providing void-free insulation after final curing
• Blocking felts stabilize end-windings, reducing vibration-induced wear during operation
• When impregnated with compatible resins, they create rigid structures that maintain coil geometry throughout the service life

Slot Liners

Creating the crucial interface between stator core steel and coil insulation, slot liners:

• Prevent abrasion damage to ground wall insulation during installation
• Provide an additional dielectric barrier between coils and grounded components
• Facilitate heat transfer from windings to the core for improved thermal management
• Maintain consistent positioning of coils within slots for optimal electromagnetic performance

Electrolock’s Engineering Approach Drives Success

At Electrolock, we understand that optimal coil insulation requires a comprehensive engineering approach rather than simply specifying individual materials. Our process includes:

• Detailed application analysis to define performance requirements
• Material selection based on electrical, thermal, and mechanical demands
• Prototype development and comprehensive testing
• Production implementation with rigorous quality controls

Our testing capabilities allow validation of critical parameters, including dielectric strength, partial discharge inception voltage, thermal conductivity, and mechanical integrity — ensuring that materials perform as expected under actual operating conditions.

Contact our engineering team today to explore how optimized coil insulation solutions can enhance the performance of your motor and generator designs.

Custom Solutions for Your Specific Applications: Reach out to the Electrolock team today to begin discussing your next electrical insulation project.

What Is Lay Flat Tubing?

Lay flat tubing is a flexible, thin-walled insulation solution that, as the name suggests, can be stored flat when not in use. This configuration offers advantages in storage efficiency and ease of handling compared to rigid or spiral wound tubing options, while providing excellent protection when deployed. The flattened configuration allows for efficient processing in automated manufacturing systems, making it ideal for high-volume production environments. When applied to components, the tubing can be expanded to completely encapsulate wires, batteries, connections, or other elements requiring protection.

Material Options: PET and PVC

Polyethylene Terephthalate (PET)

PET-based lay flat tubing provides an excellent balance of electrical and mechanical properties, making it suitable for a wide range of applications. This material offers good dielectric strength combined with excellent mechanical durability and chemical resistance. PET tubing is particularly valuable in battery applications requiring cost-effective, reliable insulation with moderate temperature requirements.

• High Dielectric Strength: Provides excellent electrical insulation properties, critical for medium voltage environments
• Temperature Performance: Shrinks at approximately 60°C, making it suitable for automated manufacturing processes
• Thin Wall Capability: Can be manufactured with extremely thin walls (as low as 0.002″), maximizing space efficiency in compact designs
• Abrasion Resistance: Offers excellent mechanical durability against wear and physical stress
• Low Moisture Absorption: Maintains insulation integrity in humid operating conditions

At Electrolock, our PET layflat tubing is represented most often in our 740 HS product offering.

This lineal seal tubing comes as heat shrink sleeves with an extremely thin wall that provides both dielectric protection and physical toughness. 740 HS tubing is composed of a one-sided, anti-static treated modified polyester (PET) film that is clear in color but can be printed on or colored. Formed into tubing, 740 heat shrink sleeves shrink quickly — roughly in 10 seconds at 100°C — and uniformly around cylindrical shapes.

Polyvinyl Chloride (PVC)

PVC lay flat tubing offers exceptional flexibility and resistance to oils, acids, and many solvents. Its dielectric properties make it an excellent choice for applications requiring protection against electrical shorts and interference. PVC tubing is often selected for environments where chemical exposure is a concern.

• Moderate Dielectric Strength: Suitable for standard voltage applications
• Chemical Resistance: Good protection against common solvents and chemicals
• Flexibility: Maintains pliability even at lower temperatures
• Cost-Effectiveness: Provides reliable performance at a lower price point
• Customization Options: Available in numerous colors for identification and coding purposes

Critical Applications Using Lay Flat Tubing

Battery Insulation

In modern battery systems, lay flat tubing plays a crucial role in preventing cell-to-cell shorts and enhancing overall pack safety. PET tubing is particularly valuable in these applications due to its:

• Ability to provide complete coverage for jelly roll insulation
• Superior dielectric protection for tab and lead insulation
• Compatibility with automated manufacturing processes, reducing the risk of foreign object debris (FOD)
• Space-efficient design that maximizes energy density in constrained battery packs

Electric Vehicle Components

Lay flat tubing protects critical wiring harnesses, busbars, and high-voltage connections from thermal stress, vibration, and potential moisture exposure. The tubular design allows for complete encapsulation of sensitive components while maintaining flexibility for complex routing requirements.

• Protection for high-voltage busbars and connections
• Insulation for wire harnesses in crowded EV component assemblies
• Heat-shrink application that creates tight, secure seals against moisture and contaminants
• Flame-retardant options that enhance overall vehicle safety

Electronics and RTD Sensors

For sensitive electronic components like Resistance Temperature Detectors (RTDs), lay flat tubing delivers targeted protection:

• Precise, uniform coverage that maintains sensor accuracy
• Excellent dielectric properties that prevent signal interference
• Thin-wall designs that minimize thermal insulation effects on temperature readings
• Clean installation without adhesive residues that could affect sensitive electronics

Find Exactly What You Require: Explore our power generation product table to view insulation solutions across the spectrum.

Explore Electrolock’s Custom Solutions

With over 65 years of experience in electrical insulation technologies, Electrolock approaches lay flat tubing with an engineering mindset tailored to each client’s specific requirements. Our comprehensive services include:

• Material selection guidance based on application-specific performance needs
• Custom sizing and wall thickness specifications
• Color-coding and custom printing capabilities for component identification
• Quality testing and validation to ensure performance reliability
• Full manufacturing support from prototyping through high-volume production

Understanding that each application presents unique challenges, our team works directly with clients to develop insulation solutions that optimize both performance and manufacturing efficiency.

Contact Electrolock today to discuss how our engineered lay flat tubing solutions can enhance the reliability and efficiency of your electrical insulation systems.

Why are Thermal Propagation Barriers Important?

These barriers (and the materials used to create them) are essential in limiting the impact should thermal runaway occur. They help prevent damage to the battery itself and provide cell-to-cell and cell-to-vehicle protection.

Impeding Thermal Runaway

Lithium-ion systems and batteries can be susceptible to thermal runaway. Thermal runaway is when a battery’s temperature increases rapidly and uncontrollably. The process can ignite fires and even cause explosions, damaging the battery and vehicle while putting the safety of the user at risk. To combat thermal runaway, insulation solutions are used, preventing overheating and the spreading of that heat from one cell to another, ultimately reducing or limiting damage.

Preventing Damage from Temperature Changes

These systems also have an optimal operating temperature. While they can function in temperatures outside of this range, it may cause damage to the battery. When functioning in extremely cold or extremely hot temperatures, the battery may get too hot or have to work too hard for the system to function properly. This can cause the battery to overheat, potentially leading to thermal runaway, or it may simply damage the battery. Luckily, with the proper thermal propagation barriers in place, your battery will be less susceptible to changes in temperature that may damage it.

Electrolock’s Thermal Propagation Barriers

Electrolock offers various thermal management solutions that can improve the safety and efficiency of your lithium battery systems.

Mica Insulation Solutions

Mica offers exceptional electrical insulation and thermal stability. With it being able to resist high temperatures and being flame resistant, this material is a great solution for thermal management in lithium-ion battery systems. It also offers excellent resistance to electrical tracking, high dielectric strength, and dimensional stability.

PET

PET offers good electrical insulation properties and mechanical strength. It is also a lightweight, flexible material that can adapt well to various cell formats and manufacturing processes. PET also exhibits good chemical resistance and is stable across a broad range of temperatures. This is also one of the more cost-effective insulation materials.

Ceramic

Ceramic insulation solutions excel in extreme temperatures, as they will not break down. Ceramic materials are suitable for high-stress applications and applications that require superior thermal management. These solutions are ideal for use where preventing thermal runaway is paramount.

How to Know Which of the Above is Right for Your Applications?

In order to choose the optimal thermal propagation barrier materials, you will need to evaluate several factors. First, you will need to determine the properties of your operating environment, including maximum and minimum temperature requirements, whether there will be exposure to chemicals, and mechanical stress levels. Then you will need to evaluate the performance requirements. This includes the dielectric strength needs, thermal conductivity targets, required service life, and safety standard compliance. Finally, you need to consider manufacturing, including how to integrate with your existing processes, material handling requirements, production volume implications, and total cost of ownership.

When You Need Thermal Propagation Barriers, Turn to Electrolock

Since 1957, our team has been engineering battery insulation systems for batteries, medium and high-voltage applications, and more. We take into consideration the exact parameters of your project and application to match you with the right material, or create the right material for you. We also maintain comprehensive testing capabilities to validate your material’s performance under specific operating conditions.

Contact our team today to learn more, or visit us at the 2025 Battery Show – Europe in Stuttgart, Germany from June 3-5. We will be at booth 8-D71.

What Is Thermal Runaway?

Thermal runaway is what occurs when an individual cell’s internal temperature rapidly and uncontrollably increases. This can cause the cell to catch fire or even explode, leading to damage to the battery and the vehicle, and putting the users’ safety at risk.

How to Mitigate Thermal Runaway

One of the better options to limit the impact of thermal runaway is to use premium insulation materials for your EV battery packs. Proper insulation prevents the heat or flame generated in one cell from propagating to another. Improving thermal runaway protection greatly reduces the cascading effect across other cells and allows for extra time for occupants of a vehicle to exit without being harmed.

Mica as a Thermal Runaway Insulator

While there are many materials that can be used for thermal runaway protection, the most popular option is mica. Mica creates a premium flame and heat barrier that can withstand the intensity of a thermal runaway event. Various thicknesses can be designed to withstand the thermal runaway event from a specific type of cell (18650, 21700, 26650, 4680, LiFePO4, pouch cells).

Mica has many benefits, including:

• High thermal stability/operating temperature
• Low thermal conductivity
• UL 94 V-0 fire resistance
• Lowest cost of any thermal runaway barrier

Mica can be used in various applications in the battery pack. Applications include cell and module barriers, insulating the inside perimeter of the battery pack, and the battery pack lid. Mica is also used as a flexible wrap on parts of the pack such as busbars and wire harnesses.

Further Advantages of Mica in Thermal Runaway Protection

High Voltage Resistance

In addition to its capabilities as a flame and thermal runaway barrier, mica also performs very well as a dielectric barrier. Mica products are commonly used as a primary dielectric barrier in battery packs, as well as in high voltage applications, including generators, motors, and wire and cable products.

High Thermal Stability and Fire Resistance

When a cell goes into thermal runaway, the intensity of the flame and gas, plus the molten metals ejected from the cell, can erode through most thermal runaway barriers in a matter of seconds. Temperatures can reach as high as 1200℃. Mica can easily withstand the high temperatures from the gas and flame, and when designed to the correct thickness, can withstand the intensity of the cell ejecta.

High Degree of Design Flexibility

Mica provides high flexibility of design for your EV battery insulation solutions. It can be created in thin, flexible tapes and sheets that are ideal for use in curved surfaces or areas with high geometric complexity. This material can also be provided in rigid panels that can be punched into parts for specific areas within a battery pack. Options include:

• Rigid — between modules or the inside perimeter walls of the battery pack
• Flexible — inside perimeter walls of the battery pack where conformability is required
• Rigid shapes — Molded to shapes to conform to internal components of the battery pack
• Tapes — Wrappable for solutions like busbar

Sustainability and Responsibly Sourced

There is concern for the sustainability and responsible sourcing of mica. Electrolock can offer mica options that address both of these concerns. Ask us about these options for the projects you are working on.

Cost Effectiveness

Mica is the lowest cost thermal runaway barrier. It is also the most common option for this type of protection.

Want to Learn More About Mica as a Thermal Runaway Protection Solution?

If you are looking for more information about mica as a thermal runaway protection solution for your EV batteries, Electrolock is here to help. Our team of experts has been engineering solutions for battery, high-voltage, and thermal insulation industries since 1957. With our extensive experience, we know how to design and manufacture the EV battery thermal runaway protection solutions you need.

Contact our team today to learn more, or talk to our experts in person this spring. We will be on hand at The Battery Show South in Atlanta, April 16-17. The Electrolock team will also be exhibiting at the 2025 Battery Show – Europe in Stuttgart, Germany, from June 3-5. We will be at booth 8-D71.

Let’s examine some of the material options for electrical insulation and the performance considerations that impact the decision-making process when designing an insulation solution.

Creating Bespoke Insulation Solutions is What We Do: Reach out to the Electrolock team today to begin discussing your next electrical insulation project.

Types of Electrical Insulation Begin with Primary Materials

Mica-Based Solutions

Mica remains a cornerstone of electrical insulation, particularly in high-voltage and high-temperature applications. Its natural crystalline structure provides exceptional dielectric strength and thermal stability. Mica materials excel in applications requiring sustained performance under extreme conditions, offering superior resistance to partial discharge and maintaining their insulative properties at elevated temperatures.

Polyethylene Terephthalate (PET)

PET-based insulation provides an excellent balance of electrical and mechanical properties. These materials offer good dielectric strength combined with mechanical durability and chemical resistance. PET solutions prove particularly valuable in applications requiring cost-effective, reliable insulation with moderate temperature requirements. Their flexibility and adaptability make them suitable for various manufacturing processes.

Fiberglass Insulation

Fiberglass materials offer robust electrical insulation properties with excellent thermal resistance capabilities. These materials combine strong dielectric performance with remarkable mechanical durability and dimensional stability. Fiberglass solutions are particularly effective in applications requiring consistent performance across fluctuating temperatures while maintaining structural integrity. Their versatility and cost-effectiveness make them a standard choice across numerous industrial applications where reliability is paramount.

Silicone-Based Materials

Silicone insulation materials offer exceptional flexibility and temperature stability. Their ability to maintain performance across a wide temperature range, combined with excellent weathering resistance, makes them ideal for outdoor and environmentally challenging applications. Silicone solutions also provide good corona resistance in high-voltage applications.

Performance Considerations for Electrical Insulation

Thermal Management

Different applications demand various levels of thermal performance. While some materials like ceramic and mica can handle extreme temperatures, others provide more moderate thermal protection. Understanding operational temperature requirements helps determine appropriate material selection.

Voltage Requirements

Dielectric strength varies significantly among insulation materials. High-voltage applications often require materials like mica or specially engineered composites, while lower-voltage applications might be well-served by more standard solutions. Voltage stress distribution and partial discharge resistance become increasingly important at higher voltages.

Environmental Factors

Environmental conditions significantly impact insulation material selection. These include factors such as:

• Moisture exposure
• Chemical presence
• UV radiation
• Physical stress
• Operational cycling

All influence optimal material choice and system design.

Custom Solution Development

While standard insulation materials serve many applications effectively, complex requirements often demand customized solutions. Developing optimal insulation systems requires careful consideration of multiple factors:

• Operating environment specifications
• Performance requirements
• Manufacturing constraints
• Cost considerations
• Maintenance requirements

Engineer the Right Solution with Electrolock

Electrolock’s extensive experience with many types of electrical insulation materials enables informed guidance through the selection process. Our engineering team works directly with clients to analyze specific application requirements and develop appropriate solutions, whether utilizing standard materials or creating custom configurations.

We maintain comprehensive testing capabilities to validate material performance under specific operating conditions. This ensures that selected insulation solutions meet both immediate performance requirements and long-term reliability needs.

From basic electrical isolation to complex thermal management challenges, our material expertise helps clients navigate the wide range of available options to find optimal solutions. We understand that each application brings unique demands, and we’re committed to developing insulation systems that deliver reliable performance.

Contact Electrolock to discuss your insulation requirements and leverage our expertise in material selection, testing, and custom solution development.

Since 1957, Electrolock has developed innovations that have played a crucial role in improving coil performance. Today we’ll take a closer look at motor coil insulation and the types of solutions we use to create ideal insulation solutions.

Creating Bespoke Insulation Solutions is What We Do: Reach out to the Electrolock team today to begin discussing your next electrical insulation project.

Key Components of Modern Motor Coil Insulation

Today’s motor coil insulation systems integrate multiple protective elements to ensure reliable operation. Ground wall insulation systems, typically incorporating high-performance mica tapes, provide fundamental electrical isolation while maintaining thermal stability. Corona suppression solutions, essential in high-voltage applications, prevent partial discharge damage and extend motor life. Phase insulation and conductor protection complete the system, ensuring comprehensive protection throughout the motor assembly.

Advanced Material Solutions

Recent developments in insulation materials have significantly expanded design possibilities. Mica-based solutions continue to excel in high-voltage applications, offering superior dielectric strength and thermal stability. When properly engineered, these materials optimize ground wall thickness while improving voltage endurance.

High-performance polymers, including Nomex® and Polyimide materials, provide exceptional mechanical strength and thermal resistance. These materials prove particularly valuable in applications requiring continuous operation at elevated temperatures, such as electric vehicle motors. Combining multiple materials, composite systems can be engineered to address specific operational challenges while maintaining optimal performance characteristics.

Critical Performance Factors for Motor Coil Insulation

Successful motor coil insulation design requires careful consideration of multiple performance factors. Thermal management capabilities must account for continuous operating temperatures and temporary excursions during peak loads. Voltage endurance characteristics ensure reliable operation throughout the motor’s service life, while mechanical strength protects against vibration and physical stress.

Environmental protection has become increasingly important, particularly in applications where motors operate in challenging conditions. Modern insulation systems must resist chemical exposure, moisture infiltration, and other environmental factors while maintaining their core protective properties.

Implementation and Quality Assurance

Selecting and implementing appropriate insulation solutions requires a systematic approach. Material selection must consider not only electrical and thermal requirements but also manufacturing processes and cost constraints. Comprehensive testing programs, including electrical, thermal, and mechanical validation, ensure that insulation systems meet performance requirements under actual operating conditions.

Custom solution development often proves valuable when standard materials cannot fully address application requirements. This process involves careful analysis of operational parameters, material capabilities, and manufacturing considerations to create optimal insulation systems for specific applications.

Electrolock: Supporting Your Success with Motor Coil Insulation

Electrolock brings extensive experience in developing and implementing advanced motor coil insulation solutions. Our comprehensive range of materials, from mica tapes and ground wall insulation to corona suppression systems and phase protection materials, enables the development of optimized solutions for specific applications.

Because Electrolock covers every aspect of motor and high voltage insulation, it can address all the major processes used in constructing coils — and find the right insulation system and products to ensure their operation.

Our engineering team partners with clients throughout the development process, from initial material selection through final implementation. This collaborative approach, combined with our testing and manufacturing capabilities, ensures that insulation solutions meet both performance requirements and practical constraints.

Contact Electrolock to discuss your motor coil insulation requirements and discover how our materials expertise can enhance your motor design’s reliability and efficiency.

Today we’re taking a closer look at different types of materials and in what cases they could serve as the ideal solution for your battery cell insulation needs. Let’s get started.

Creating Bespoke Insulation Solutions is What We Do: Reach out to the Electrolock team today to begin discussing your next electrical insulation project.

Core Functions of Battery Cell Insulation

Battery cell insulation serves multiple critical functions in modern battery systems. These materials must provide reliable electrical isolation between cells while managing thermal transfer and offering mechanical protection. Effective insulation prevents short circuits, helps maintain optimal operating temperatures, and protects against physical stress during normal operation and potential failure events — such as thermal runaway.

Mica-Based Insulation Materials

Mica stands out in battery applications due to its exceptional electrical insulation properties and thermal stability. This natural mineral-based material maintains its insulative properties at high temperatures and offers excellent resistance to electrical tracking. Mica-based solutions prove particularly effective in applications requiring extended exposure to elevated temperatures.

Key advantages of mica include its high dielectric strength, flame resistance, and dimensional stability. These properties make it ideal for high-power battery systems where thermal management is critical. While mica solutions may carry a higher initial cost compared to some alternatives, their durability and reliable performance often justify the investment in demanding applications.

PET-Based Solutions

Polyethylene terephthalate (PET) insulation materials offer a balanced combination of performance and cost-effectiveness. These materials provide good electrical insulation properties and mechanical strength while remaining lightweight and flexible. PET solutions adapt well to various cell formats and manufacturing processes.

PET insulation materials demonstrate strong chemical resistance and maintain stability across a moderate temperature range. Their cost-effective nature and ease of integration make them particularly suitable for medium-duty applications where extreme temperature resistance isn’t critical. PET’s versatility allows for various manufacturing methods, including custom-shaped barriers and sleeves.

Ceramic Insulation Options

Ceramic insulation materials excel in extreme temperature environments and applications requiring superior thermal management. These materials offer exceptional heat resistance and can maintain their insulative properties under severe conditions. Ceramic solutions particularly suit high-stress applications where thermal runaway prevention is paramount.

While ceramic materials typically represent a higher-cost option, their unmatched thermal properties and longevity prove valuable in critical applications. Their rigid nature requires careful consideration during the design and integration phases, but their reliability in extreme conditions often outweighs these challenges.

Battery Cell Insulation Selection Criteria and Considerations

Choosing the optimal insulation material requires careful evaluation of several factors. Here’s a quick checklist of considerations you should have in mind before selecting a specific material:

Operating Environment

• Maximum and minimum temperature requirements
• Exposure to chemicals or contaminants
• Mechanical stress levels

Performance Requirements

• Dielectric strength needs
• Thermal conductivity targets
• Required service life
• Safety standards compliance

Manufacturing Considerations

• Integration with existing processes
• Material handling requirements
• Production volume implications
• Total cost of ownership

For Battery Cell Insulation and Much More, Turn to Electrolock

Selecting the right battery cell insulation material significantly impacts system performance, safety, and cost-effectiveness. While mica offers superior thermal stability and electrical isolation, PET provides cost-effective solutions for moderate applications, and ceramic materials excel in extreme conditions.

Electrolock’s extensive experience in battery insulation materials enables informed guidance through the selection process. Our engineering team works directly with clients to analyze application requirements and recommend optimal solutions, whether standard or custom. We maintain comprehensive testing capabilities to validate material performance under specific operating conditions.

Contact Electrolock to discuss your battery cell insulation needs and leverage our expertise in material selection, testing, and custom solution development. Our technical team can help ensure your insulation choice aligns with both performance requirements and operational constraints.

Custom Solutions for Your Specific Applications: Reach out to the Electrolock team today to begin discussing your next electrical insulation project.

Fundamental Principles of Electrical Insulation

At its core, electrical insulation serves to prevent the uncontrolled flow of electrical current between conductors. In industrial applications, this means containing electrical energy within its intended path while protecting surrounding components and operators. Effective insulation materials must demonstrate specific properties including high dielectric strength, thermal stability, and mechanical durability. These characteristics become particularly critical in environments with extreme temperatures, high voltage loads, or constant mechanical stress.

The Importance of Electrical Insulation for Critical Applications in Modern Industry

High-voltage applications demand precise insulation solutions to maintain operational integrity. Power distribution equipment requires carefully engineered insulation systems to prevent electrical breakdown and ensure consistent performance. Industrial machinery often operates under demanding conditions where insulation failure could lead to equipment damage or workplace hazards. Professional-grade insulation materials and proper installation methods are essential for maintaining safe, efficient operations.

Battery technology presents unique insulation challenges, particularly in electric vehicle applications and industrial energy storage systems. Effective battery insulation must address both electrical and thermal concerns. Proper insulation in battery systems prevents short circuits, manages cell-to-cell thermal transfer, and helps maintain optimal operating temperatures. This dual functionality makes material selection and design particularly critical for battery applications.

Thermal protection represents another crucial aspect of industrial insulation. Many industrial processes generate significant heat that must be managed to protect equipment and maintain efficiency. Thermal insulation works alongside electrical insulation to create comprehensive protection systems. This integration is particularly important in applications where electrical equipment operates at high temperatures or where thermal runaway could pose serious risks.

Choosing the Right Insulation Solutions

Selecting appropriate insulation materials requires careful consideration of multiple factors. Operating temperature range, voltage requirements, mechanical stress, and environmental conditions all influence material selection. Standard insulation products may suffice for common applications, but many industrial processes benefit from customized solutions that address specific operational challenges.

Material options range from traditional mica tapes and process films to specialized composites designed for extreme conditions. Each material offers distinct advantages in terms of temperature resistance, dielectric strength, and mechanical properties. Professional consultation often proves valuable in matching insulation materials and designs to specific application requirements.

High voltage testing plays a crucial role in validating insulation performance. Proper analytical testing can verify dielectric strength, thermal resistance, and mechanical durability under simulated operating conditions. These tests help ensure that selected materials will perform reliably in real-world applications and meet required safety standards. Regular testing throughout the development process helps identify potential issues before they become operational problems.

At Electrolock, We Believe in the Importance of Electrical Insulation

Proper electrical insulation stands as a cornerstone of industrial equipment reliability and safety. Whether dealing with high-voltage systems, battery applications, or thermal management challenges, choosing the right insulation solution directly impacts operational success.

Electrolock brings decades of experience in developing and manufacturing high-performance insulation solutions for demanding industrial applications. With comprehensive capabilities in material selection, custom design, and high-voltage testing, Electrolock partners with clients to create optimal insulation solutions for their specific needs. From standard products like mica tapes and process films to custom-engineered solutions for unique applications, Electrolock’s technical expertise ensures reliable performance in critical industrial operations.

Contact Electrolock’s engineering team to discuss your specific insulation requirements and discover how our testing and manufacturing capabilities can support your operational success.

What is Thermal Runaway?

Thermal runaway occurs in lithium-ion batteries when the temperature within the battery cells increases and leads to a series of exothermic reactions. These reactions continue to increase the temperature of the battery, and can even cause other battery cells to overheat.

Not only can thermal runaway damage batteries and impact their function, but it can cause serious damage to property and hurt individuals. The heat can start fires within the battery and even lead to explosions.

How Lithium-Ion Battery Insulation Systems Can Prevent Thermal Runaway

Since thermal runaway is caused by overheating in battery cells and that heat being passed to other battery cells, lithium-ion battery insulation systems are one of the best ways to prevent thermal runaway from occurring. These insulation solutions can stop excess heat from being transferred to other battery cells, keeping the thermal runaway from spreading and getting worse.

Lithium-ion batteries can also be impacted by external temperatures. Whether hot or cold, these batteries may be susceptible to damage. Insulation also keeps batteries from getting too hot in the heat and getting too cold in freezing temperatures.

Lithium-Ion Battery Insulation Solutions

There are a few materials that are often used to insulate lithium-ion batteries. Some of the most common solutions include:

Mica

Mica has high thermal stability, low conductivity, and is non-flammable. This allows it to create a barrier between battery cells, preventing the risk of overheating and ensuring electrical integrity.

Polyester

Polyester exhibits good electrical insulation, thermal resistance, and dimensional stability. It is also a good dielectric barrier that can withstand high temperatures. All of these properties allow the material to prevent the flow of electricity and heat from one battery cell to another.

Polypropylene

Polypropylene has a high heat resistance, electrical resistance, and low thermal conductivity. These properties make it an ideal choice for insulation for battery cells.

Silicone

Exhibiting low thermal conductivity and having a wide temperate range allows the silicone to be used as a thermal runaway barrier and interior battery pack liners.

Polyimide

Polyimide has excellent heat stability, electrical, and mechanical characteristics, giving it the ability to be used as a dielectric barrier to prevent thermal runaway.

When You Need Lithium-Ion Battery Insulation, Electrolock Has the Options You Need

Since 1957, Electrolock has been engineering battery insulation solutions that keep products running smoothly and safely. In addition to our solutions offerings, we can also work closely with you to design and manufacture a solution that fits all of your needs.

Contact our team today to see what we can do for you.

How Does Thermal Insulation Work?

Thermal insulation is used to maintain temperatures in specific environments. These materials can do this by limiting the rate of heat flow between objects or substances. Materials with low thermal conductivity provide the highest-performance insulation; however, there are a few other properties that can contribute to the effectiveness of the insulation including density, thickness, and specific heat capacity.

What is the Purpose of Thermal Insulation

The main purpose of thermal insulation is to reduce the amount of heat lost or gained through a system. There are additional purposes that are specific to their applications:

Preventing Thermal Runaway

Thermal runaway is an extremely dangerous phenomenon that occurs in lithium-ion batteries. It starts when heat is generated within a battery and that heat exceeds the amount that is dissipated to its surroundings. The battery temperature will keep rising, causing the current to rise as well. This starts a domino effect of rising temperatures which can spread to other battery cells, causing fires or explosions.

Thermal insulation solutions prevent the heat from escaping the affected battery cell, preventing additional cells from overheating and ultimately reducing the risk of thermal runaway. This makes your lithium-ion battery-powered products safer and more reliable.

Maintaining Temperatures in Heated Tube Bundles

Heated tube bundles are used in a wide range of industries, including HVAC, power generation, and industrial processes. These bundles transfer heat between fluids. Insulation materials allow for very little heat to be lost, keeping the heated tube bundles at the ideal temperature.

Protects Heat-Sensitive Products

Products that are sensitive to heat need to be kept at the ideal temperature in order for them to function properly. Thermal insulation can be used to prevent heat from being lost or gained, keeping these products at their necessary temperature.

Thermal Insulation Material Offerings

Many materials can be used as thermal insulation. Based on the needs and environment of your application one material may be better than others. Here are some of the most common materials:

Fiberglass

Fiberglass is composed of fine glass fibers and is commonly used as a thermal insulation solution. Within the fiberglass, pockets of air are trapped, disrupting the flow of heat from one place to another, acting as an insulator.

Mica

Mica has many properties that make it an ideal insulator. Not only can it resist high temperatures and is non-flammable, but it also exhibits low thermal conductivity. This material is also resistant to chemicals and has high tensile strength making it common for use in many industries.

Are You Looking for Thermal Insulation Solutions? Contact Electrolock

At Electrolock, we have been engineering thermal insulation solutions since 1957. We carry a wide range of products and materials to meet all of your needs. Plus, if you can’t find the perfect solution, our team is ready to work with you to design and manufacture a solution that fits your exact requirements.

Contact our team today to get started.

From October 7-10, 2024, our team will be at Huntington Place in Detroit, Michigan showcasing our innovative battery insulation solutions. At this event, you will not only get to learn about our latest battery solutions, but you will have access to the latest from over 1,150 battery manufacturers across the industry.

During this four-day event, you will be able to attend workshops and conferences to learn more about the insulation solutions that can best fit the needs of your battery application.

Register today!

What Battery Insulation Solutions Are We Bringing?

At Electrolock, we know that thermal runaway is extremely dangerous and puts companies in a bad light. Our offerings are specifically designed to reduce the risk of thermal runaway in batteries.

We have many battery insulation solutions including mica, polyester, polypropylene, silicone, and polyimide options. Each of these options properly insulates batteries, however, they do have different properties.

• Mica exhibits high thermal stability, and low thermal conductivity, and is non-flammable while creating a barrier that ensures the electrical integrity of battery cells
• Polyester has good electrical insulation, thermal resistance, and dimensional stability, and is a good dielectric barrier with high-temperature resistance
• Polypropylene is used as a batter separator because it has high heat resistance, electric resistance, and low thermal conductivity
• Silicone has low thermal conductivity and can be used in a wide range of temperatures
• Polyimide exhibits excellent heat stability and electrical and mechanical characteristics

You will have the opportunity to see and learn about all of the battery insulation solutions we offer at The Battery Show. And, if you don’t see anything that meets all of your needs, our team will work closely with you to design and manufacture the battery insulation solution that works for you.

Come Visit Electrolock at The 2024 Battery Show

Learn more about the event here, and make sure to come visit Electrolock at Exhibit Hall A-C 4214. Register for the 2024 Battery Show in Detroit, Michigan today!

Types of Cable Insulation Tests

Analytical Testing

This insulation testing method is used to identify, examine, evaluate, and compare insulation materials for your applications. Analytical testing assesses the chemical, electrical, mechanical, and thermal properties of insulation materials to determine which will work best for your application.

Multiple types of analytical tests are typically done with a variety of tools and metrics, including:

• Differential Scanning Calorimeter: measures temperatures and heat flow associated with thermal transitions in materials
• Dynamic Mechanical Analyzer: applies stress to a material to determine its resulting strain or stress response
• Fourier Transform Infrared Spectroscopy: uses infrared light to identify materials
• MTS Tensile: used to determine the amount of tensile, torsion, compression, and flexure a material can withstand
• Gurely Densometer: measures the porosity of materials to determine how much gas and liquid can pass through
• Gurely Bending Resistance Tester: tests the stiffness of your insulation material and the amount of bending they can withstand
• Contact Angle Meter: measures the wettability of a material by applying drops of various liquids to the material
• Muffle Furnace: used to determine the percentage of inorganic material in an insulation material

High-Voltage Testing

High-voltage testing helps develop insulation systems. They test for dissipation factor, voltage endurance, voltage breakdown, and partial discharge. Many tests are done during high-voltage testing, including:

• Hipotronics Hipot Tester: tests the dielectric strength of the insulation to ground, determining whether the ground wall can handle an over-voltage situation

• Megohm Bridge: measures the resistance of a material by sending a high-voltage signal into the material

• Capacitance Bridge: used to identify an unknown or unlabeled capacitor

• Dissipation Factor Testing: electrical test that defines the condition of an insulating material

Why Are Cable Insulation Tests Important?

Cable insulation testing is crucial to ensuring that your cables and wires are safe and will function efficiently. These tests can help prevent shock, short circuits, and other dangerous outcomes by determining which solution is best for your application. Whether it is testing your current insulation to make sure it functions as you expect or if you are looking for a way to design and create an insulation solution for your needs, cable insulation testing is an important part of your cable insulation project.

Electrolock Has the Expertise and Equipment Needed to Perform All of Your Cable Insulation Tests

Since 1957 Electrolock has been engineering insulation solutions for high-voltage electrical, cables, batteries, and more. Part of our services include analytical and high-voltage testing for your insulation materials. This ensures that we are designing the right insulator for your needs to function efficiently and safely.

In addition to our extensive testing services, we also engineer and manufacture insulation solutions to fit all of your specifications. Our team will consider the application and environment of your products, as well as any other crucial information, and design the insulation material that checks all of your boxes. From battery insulation to high-temperature wire and cable insulation to high-voltage insulation, we have everything you need.

Contact our team today to get started.

Most plug-in hybrids and EVs use lithium-ion batteries to run. These batteries are chosen for their high power-to-weight ratio, high energy efficiency, good high-temperature performance, long life, and low self-discharge. However, lithium-ion batteries do have their challenges. To keep these vehicles running smoothly, efficiently, and safely, we need to make sure that their batteries are optimized for performance. This is where EV battery insulation comes in.

Why is EV Battery Insulation Important?

EV batteries present several risks that both manufacturers and users need to be aware of and understand so the safety, reliability, and longevity of these vehicles are never in question.

Thermal Runaway

Thermal runaway occurs when the battery’s temperature rapidly and uncontrollably increases. When this happens, fires and explosions are extremely likely, causing damage to the vehicle and putting the users’ safety in danger.

Luckily, insulation can help. The right EV battery insulation can prevent the heat from one battery cell from jumping to another, greatly reducing the risk of thermal runaway and the damage the process may cause.

Environmental Conditions

Extreme temperatures in the environment can also impact the battery’s performance and safety. While high temperatures can increase the risk of thermal runaway, low temperatures can reduce the efficiency and range of the vehicle.

The proper EV battery insulation solution will help regulate the temperature of the battery. By keeping the temperature of the battery relatively consistent, you will be able to increase the functionality, efficiency, and safety of the EV.

Damage to the Battery

Insulation solutions can also help prevent damage to the battery in the event of an accident. When the batteries are scraped or damaged in any way, the chances of thermal runaway occurring increase. Insulation can protect the battery from these damages by providing an extra layer of material that acts almost as a cushion.

EV Battery Insulation Solutions

There are many EV battery insulation solutions on the market, let’s review some of the common materials that are ideal for use in these applications:

Mica

Mica creates a barrier that ensures the electrical integrity of each battery cell, reducing the risk of thermal runaway. This material exhibits high thermal stability and low thermal conductivity while being non-flammable.

Polyester

Polyester is commonly used as a separator material in batteries to prevent short-circuiting between the positive and negative electrodes. This material exhibits good electrical insulation, thermal resistance, and dimensional stability while being a good dielectric barrier and being able to withstand high temperatures. Some of the EV battery insulation solutions made from polyester include cell wrappers, heat shrink polyester sleeving, top and bottom cell insulators, and outside cell insulators.

Polypropylene

This material is commonly used as a battery separator due to its high heat resistance, electric resistance, and low thermal conductivity. Cell wrappers, top and bottom cell insulators, and jelly roll wraps are made from polypropylene.

Silicone

Silicone is a natural insulator that exhibits low thermal conductivity and can be used in a wide temperature range. This material is commonly used to create thermal runaway barriers and interior battery pack liners.

Polyimide

Polyimide has excellent heat stability and good electrical and mechanical characteristics. Cell wrappers, jelly roll wrappers, and dielectric barriers are commonly made from polyimide.

If You Need EV Battery Insulation, Turn to Electrolock

Electrolock has been engineering high-voltage electric, battery, and thermal insulation solutions since 1957. Our team has many options to meet the needs of your EV battery insulation needs, however, if you can’t find a solution that is just right, our team will work with you to design and manufacture a solution that fits all of your criteria.

Contact our team today to see what we can do for you.

Desirable Properties of Thermal Insulation Materials

Dielectric Strength

Dielectric strength describes the amount of voltage an insulation material can withstand before breaking down. Thermal and electrical insulation materials need to be able to resist the voltage of electricity they will be exposed to ensure the insulated part or component continues to work as intended. You will need to know the amount of voltage your application will generally be exposed to, that way you can choose the thermal insulation that has the proper dielectric strength.

Thermal Conductivity

Thermal conductivity measures how well an item allows heat to pass through it. Heat moves between objects, and sometimes can move extremely quickly causing a greater and greater increase in heat, eventually leading to extremely dangerous thermal runaway. Low thermal conductivity means that the thermal insulation material can keep heat from transferring between objects or keep the heat trapped in a desired area.

Temperature Resistance

Thermal insulation materials also need to be able to withstand high temperatures, as they are used to prevent heat from passing from one area to another. It is important to choose a thermal insulator with a high-temperature resistance so you don’t have to worry about the insulators melting within your application.

Thermal Expansion

Thermal expansion refers to the amount a material stretches or expands when it is exposed to heat. In some instances, if an insulator expands too much when it is exposed to heat, the system or battery could be compromised and will not function properly.

Fire Resistance

High heat and electricity can easily start a fire at any point in time, especially when thermal runaway occurs. Thermal insulation materials should be resistant to fire in order to keep the fire contained as much as possible. Without this resistance, any fire — even small or minor instances — could result in catastrophic damage.

Thermal Insulation Solutions from Electrolock

At Electrolock, we carry various types of thermal insulation materials and solutions to meet the needs of your applications. Some of the most common thermal insulation materials used are:

• Fiberglass: This material is available in woven, non-woven, and needled felt solutions and provides strong reinforcement, low thermal coefficient of expansion, and a high thermal performance up to 600ºC.

• • Kevlar®: These woven fabrics provide high strength and impact resistance.
  • Nomex®: This material is available in non-woven and needled felt solutions. Nomex® has an operating temperature resistance of up to 220ºC.

• PET or Polyester Films: These films are available in non-woven and needled felt solutions and provide high dielectric strength, however, they only have a thermal resistance of up to 130ºC.
• PAN: PAN is a needled non-woven high-temperature felt that exhibits good short-term flame resistance and is commonly used for thermal insulation applications.

All of our thermal insulation solutions can be backed with pressure-sensitive adhesives, foils, or flame-retardant papers and coatings so they best serve your needs.

Ready to Get Started? Contact Our Team Today

Since 1957, Electrolock has been providing innovative solutions for the high-voltage electrical, battery, and thermal insulation industries. If you can’t find something that fits your needs in our standard product offerings, our team will work with you to engineer a thermal insulation solution that fits your exact specifications.

Contact our team today to get started.

Die-cutting is a manufacturing process in which a machine uses a metal component called a die to cut specific shapes from a material. It is primarily used to create customized solutions quickly and easily, including die-cut insulators.

What are Die-Cut Insulators?

Die-cut insulators are custom-made insulation solutions. Insulators hinder the free flow of electrons and eliminate the unintended discharge of the electric current. These insulators are also used to reduce the amount of heat produced by a battery or electrical application and improve functionality.

Benefits of Die-Cut Insulators

Customization

Die-cutting allows your insulation manufacturer to create your solutions in exactly the shape and size you need. This will save you time and money down the line, as you won’t have to perform these actions yourself.

Uniformity and Reproducibility

The dies used are made from metal, making them extremely durable. This allows the die to be used repeatedly without breaking down. So, the same die can be used over and over to produce die-cut insulators that are exactly the same as many times as you need.

Complex Designs

Having to try to hand-cut insulators to meet the needs of your complex-shaped products is time-consuming and tedious. By choosing die-cut insulators, you eliminate the need to do this by hand. Plus, dies can be manufactured into nearly any shape, accommodating even the most complex of designs

What Die-Cut Insulation Options Are There?

Many different insulation options can be customized through die-cutting, however, most of these include mica tape, wire and cable insulation tape, silica tape, and cell wrappers.

Mica Tape

This insulation option includes mica paper that is laminated to various substrates. Due to mica’s high dielectric strength, low electric loss, and excellent thermal stability, it is a great choice for high-voltage applications, wire and cable insulation, and thermal insulation.

Wire and Cable Insulation Tape

These insulation solutions must withstand high temperatures and demanding environments. Mica tapes are used in these applications, however, Kapton® and Nomex® are also used due to their high-temperature resistance and electrical insulation properties.

Thermal Insulation Solutions

These solutions are used to prevent thermal runaway in batteries and protect heat-sensitive products. Thermal insulation solutions include non-woven fiberglass paper, silicone-coated fabrics, and more.

Electrolock Is Here to Help Innovate Your High Voltage Insulation Solutions

Electrolock has been engineering high-voltage, battery, and thermal insulation solutions since 1957. We can provide you with various types of electrical insulation, including high-voltage solutions, battery insulation, and more.

If you can’t find a solution that meets your needs, our team will work with you to design and manufacture a solution that fits your specifications. We can identify your problem and manufacture a solution that fits your needs. Then, we can perform analytical testing to make sure that these solutions truly meet all of your needs.

Contact our team today to get started.

What are High Voltage Insulators?

Insulators are materials that hinder the free flow of electrons. These insulators form a barrier between two energized parts of a circuit and reduce or eliminate the flow of electrons, the electric current, and heat to wires or other conducting materials. Not only are these insulating solutions used to prevent the flow of electricity and heat to areas where they are not desired, but they are also used to optimize ground wall thickness and improve voltage endurance.

What Makes a Good High Voltage Insulator?

There are a few properties that make certain materials good high-voltage insulators. Each of these properties prevents electrons and heat from transferring from one place to another.

Low Thermal Conductivity

When a material has low thermal conductivity, it is unable to conduct heat efficiently. These materials, thus, prevent heat transfer and limit the amount of free electrons in the system. Since they block heat and electrons from moving freely, they try to find other ways to transfer, all of which are significantly less efficient, thus making the system safer.

Good Dielectric Strength

Dielectric strength is the insulator’s ability to resist electrical breakdown. Since high-voltage insulators are going to be exposed to large quantities of electrical voltages, they must have a high dielectric strength to be successful.

Mechanical Strength and Durability

Many times, insulators, particularly high voltage insulators, are subjected to extreme conditions and harsh environments. These materials will need to have high mechanical strength to withstand extreme weather conditions, and they must be highly durable to have a long service life despite environmental and mechanical fatigue.

Thermal Stability

Electrical currents will generate a great deal of heat, and insulators need to be able to withstand these extreme temperatures. The best high-voltage insulation will have a high thermal stability so they do not fail or become deformed in the presence of high temperatures.

What High Voltage Insulation Options Are There?

There are many types of high-voltage insulation solutions on the market, each of which is designed to meet different needs. At Electrolock, we carry various types of high voltage insulation products.

Irradiated Polyethylene Film

Irradiated polyethylene film exhibits excellent electrical insulation, making it ideal for use as the outer sealing layer on high-voltage coils that are processed in an asphalt autoclave. At Electrolock, we carry Electrolock 525-IPB, which is a black irradiated polyethylene release film.

Mica Film

Mica exhibits low thermal conductivity and is non-flammable, making it a great option for insulation. Electrolock carries various types of high voltage insulation that include mica:

• Calmicaglas®: This insulation material consists of mica paper that is based on uncalcined muscovite or calcined muscovite. Several types of Calmicaglass® are used for the insulation of coils and bars of low and high-voltage machines, motors and generators up to the highest output and nominal voltage, electrical motors and generators, and air and indirect gas-cooled electrical machines.

• Conductofol®: This high voltage insulation solution is made of mica paper based on calcined muscovite that is impregnated with resin and a PET film. We create many types of Conductofol® that are used in the insulation of copper conductors for high and low voltage machines in various applications and environments.

Polyester

Polyester has excellent mechanical strength, wear resistance, and electrical insulating properties. Electrolock’s Contafel® is a polyester insulation option. Each of our Contafel® polyester products is uniquely tailored to various applications including protecting tapes on coils and bars for high voltage machines, VPI, and RR processes.

Electrolock Is Here to Help Innovate Your High Voltage Insulation Solutions

Since 1957, Electrolock has been engineering solutions for high voltage, battery, and thermal insulation industries. We carry many types of high voltage, battery, thermal, and wire and cable insulation solutions. And, if you can’t find a solution that meets your needs, our team will work with you to design and manufacture a solution that fits your specifications.

Contact our team today to get started.

Thermal runaway in lithium ion batteries causes many issues. This chain reaction is extremely dangerous and causes irreparable damage to your batteries. Luckily, there are a few proven ways to prevent this dangerous process.

What is Thermal Runaway in Lithium Ion Batteries and Why is it Dangerous?

Thermal runaway is a chain reaction in batteries that is extremely hard to stop once it starts. The process occurs in a battery when an exothermic reaction triggers another, resulting in an uncontrolled increase in the battery temperature. In lithium batteries, this happens when the lithium ion cell generates heat at a faster rate than it can dissipate from the cell. Thermal runaway in lithium ion batteries can cause the ejection of gas, shrapnel, and particulates, along with generating extremely high temperatures, smoke, and fire.

How to Prevent Thermal Runaway in Lithium Ion Batteries?

Proper Storage Temperature

The simplest way to prevent thermal runaway in lithium ion batteries is proper storage. Generally, the ideal storage temperature for most lithium ion batteries is between 35ºF (1.7ºC) and 90ºF (32ºC), however, the range may vary from battery to battery. Since these ranges may vary, it is important to check the battery label and take care to stay within that range as much as possible.

Replace Old Batteries

While lithium ion batteries last for years, there is a good possibility that they will degrade over time, making it crucial to change your batteries as needed. Smaller lithium ion batteries can last for 2-3 years before needing to be replaced while lithium ion batteries in EVs are designed to last 10-20 years before needing to be replaced. Regardless, it is important to keep an eye on the health of your batteries and get them replaced when needed.

Proper Insulation

One of the most effective ways to prevent thermal runaway in lithium ion batteries is to ensure they are insulated properly. Proper battery insulation can prevent the heat generated from one lithium ion battery cell from jumping to another, thus preventing thermal runaway. Electrolock offers many insulation options for lithium ion batteries:

• Go-Therm Thermal Runaway Barriers are designed to be used as an interior lining of the battery case, protecting the pack from ejecta and flame caused by thermal runaway. The Go-Therm 150 is a glass one-sided silicone laminate that is used to line the interior of the battery packs and as a thermal runaway barrier between prismatic cells. Additionally, the Go-Therm 315 is a fiberglass dual-backed insulation that is used to line the interior of the battery pack to act as a thermal runaway barrier between prismatic cells in a module or as a module-to-module barrier.
• Pyrel-Therm is a thermal runaway barrier that is designed to meet extreme heat environments. There are a few types of Pyrel-Therm that are used in battery insulation:

• Pyrel-Therm EIG 1000 exhibits excellent thermal resistance, extremely low shrinkage, low thermal conductivity, and compression resistance.

• Pyrel-Therm ES 1100 also has excellent thermal resistance, extremely low shrinkage, low thermal conductivity, and compression resistance.

• Pyrel-Therm RMC Mica Heat Shield has very low heat transfer and is an effective dielectric and gas barrier.

• Pyrel-Therm TS 800C is generally used in applications where high temperature and low thermal conductivity are required. It exhibits superior resistance to heat and flames and acts as an excellent heat shield in electronics and military applications.

Electrolock is Here to Help Prevent Thermal Runaway in Lithium Ion Batteries

Since 1957, Electrolock has been engineering insulation solutions for various industries. As lithium ion batteries become more and more common in everyday items, our team has developed numerous insulation solutions to prevent thermal runaway in these batteries to keep them running safely and efficiently.

If you are looking for thermal runaway insulation, contact our team today to get started.

Properties of Different Types of Electrical Wire Insulation

The three main types of electrical wire insulation include polyimide, Teflon®, and mica tapes. Each of these options has unique properties that make them ideal for use in electrical applications.

Polyimide

Polyimide is chosen for electrical applications due to its many advantageous properties. With the ability to withstand temperatures greater than 400ºC, or 752ºF, chemical resistance, and mechanical durability, polyimide is a great choice for demanding electrical applications.

There are two primary polyimide tapes — Apical® and Kapton®. Apical® polyimide tape has excellent mechanical properties and chemical resistance. Similarly, Kapton® polyimide tape has good mechanical properties and chemical resistance while also being flexible.

Teflon®

As an electrical insulator, Teflon® is a great choice because it can withstand temperatures up to 260ºC, or 500ºF, has good dielectric properties, and is resistant to many chemicals. There are numerous options when it comes to Teflon® tapes, all of which have desirable properties that distinguish their applications:

• FEP is tough and flexible while exhibiting good chemical resistance.
• PFA is flexible with good dielectric strength. It is resistant to stress, chemicals, and fire, and can withstand both high and low temperatures.
• PTFE is the most popular form of Teflon® and is resistant to water, chemicals, and high and low temperatures.
• Sintered Teflon® exhibits high elongation and is resistant to weathering.
• Tensilized Teflon® has great tensile strength.
• UnSintered Teflon® exhibits excellent dielectric properties.

Mica

Mica tape is commonly used in electrical applications due to its water and chemical resistance. There are two primary types of mica tape — Nomex® and Pyrodox®. Nomex® has high dielectric strength and flexibility, is resilient, and is an excellent insulator. While there are numerous varieties of Pyrodox®, they all have similar characteristics in that they are heat-treated mica tapes capable of withstanding electrical and thermal overloads in environments with high moisture.

The different types of Pyrodox® include:

• Pyrodox® GP: a phlogopite mica tape made from silicone binder with a fiberglass backing
• Pyrodox® GM: a calcined muscovite mica tape
• Pyrodox® PEP: heat-treated phlogopite mica tape with a silicone binder and a polyethylene backing
• Pyrodox® SG: synthetic mica tape with a silicone binder and a fiberglass backing
• Pyrodox® SEP: another synthetic mica tape with a silicone binder and a polyethylene backing
• Pyrodox® PET: a phlogopite mica tape with a silicone binder and a polyester backing.

Applications of Each Type of Electrical Wire Insulation

Polyimide

Apical® polyimide tapes are used in many critical applications due to their ability to withstand extreme temperatures. You can find these tapes used in commercial and military aircraft, aerospace applications, satellites, and missiles.

Kapton® polyimide tapes can be used in many applications, including wire and cable tapes, formed coil insulation, capacitor and transformer insulation, and magnetic wire insulation.

Teflon®

Each type of Teflon® has its own applications due to its structure and properties. For electrical components for computers and aircraft, FEP Teflon® is the top choice. PFA Teflon® is used in wire constructions, heater cables, heavy wall conduits, cable jacketing, and more. For more critical applications, such as military, aerospace, coaxial, and appliance wiring applications, PTFE Teflon® is a common option. Sintered Teflon® is used as conductor insulation while UnSintered Teflon® is used in capacitors, special cables, and electrical instruments. Finally, Tensilized Teflon® is commonly found in separators, transformers, slot liners, and harness wrapping.

Mica

The two types of mica tape have different uses. Nomex® is used as motor phase insulation, transformer coil fillers, motor conductor wrap, coil wrap, and transformer ground insulation. Because Pyrodox® is resistant to flame, it is used in applications where fire survival is necessary, including power cables, mass transit, aircraft, oil wells, thermocouples, appliance wires, and shipboard cables.

Electrolock Carries All Types of Electrical Wire Insulation Options

For nearly 70 years, Electrolock has been engineering solutions for various industries, including wire and cable insulation. Our materials can be used for shielding or as flame barriers, dielectric barriers, and separators. We also have experience engineering high voltage insulation materials, battery insulation, spiral wound tubing, Porex tubing, thermal insulation, and polyshrink film.

If you are looking for electrical wire insulation, contact our team today. We can help you choose the right solution for you, or engineer something new to meet all your needs.

Calcined mica tapes are designed to withstand high temperatures. At Electrolock, we take into consideration how the calcined mica tape functions in medium voltage applications, as well as applications in motors and generators.

In this blog, we’re taking a deeper look at calcined mica tape, including its properties and uses.

Why Use Calcined Mica Tapes?

Calcined mica tapes are designed to withstand tough applications and high temperatures. The calcination process is used to dehydrate the mica structure, which changes the mica papers that are eventually converted into mica tapes. These tapes are durable and provide excellent short-term dielectric breakdowns.

It should be noted that there are disadvantages to calcined mica tape, so it is not right for every application. Mica paper that is not calcined is commonly referred to as uncalcined mica paper. Before dehydrating the mica crystals there are still excellent electrical and thermal properties, however, the calcination process usually yields a smaller mica flake. This smaller flake can have tighter cross-sheet toughness, but at the same time requires more time for resins to penetrate. Uncalcined papers typically absorb resin faster even though they are more fragile to work with. Manufacturers should discuss the tradeoffs; this can be critical in a medium or high-voltage application.

For manufacturers that have already decided they need a calcined mica tape, there are still several options to choose from depending on the application. These mica papers, calcined or uncalcined, are bonded to carriers such as glass, polyester, or polyimide. A binding resin is included to keep the mica paper and the carrier from separating. Binder resins are far weaker thermally than mica paper and can ultimately decide which tape is correct for your application.

Properties and Common Calcined Mica Uses

Many calcined mica properties make it a strong material option. It provides excellent insulation due to its non-flammable nature and low thermal conductivity. Calcined mica tape is durable and because it typically has a higher binder content it can be easier to apply during the taping process. Let’s delve a little further into its other beneficial qualities.

High Temperature Resistance

During the manufacturing of this tape, the calcined mica is dehydrated to give it a better structure. In doing so, the calcined mica tape becomes stronger and more durable, giving it the ability to resist high temperatures.

Wire and Cable Insulation

In order to prevent electrical leakage, wires and cables must be properly insulated. Using calcined mica as this insulation material prevents this electrical leakage, preserves the integrity of the wire, and makes the wires and cables safe and effective.

Motor and Generator Coils

A crucial aspect of motor and generator coils is insulation. To prevent the electrical current from passing between coils or escaping the coils, proper insulation materials need to be used. Calcined mica can withstand the voltage and heat of the generators, making it a great insulation material for the wires within motor and generator coils.

If You Have Calcined Mica Uses, Turn to Electrolock

For nearly seven decades, Electrolock has been engineering and manufacturing insulation materials for various applications. Our team understands how to create insulation materials for high-voltage applications, batteries, wires and cables, high-temperature applications, and motor and generator coil insulation.

Calcined mica tapes are designed to withstand high temperatures. We take into consideration how the calcined mica tape functions in medium-voltage applications, as well as applications in motors and generators.

In addition to our ability to create calcined mica tape, we create high-voltage insulators, battery insulation, spiral wound tubing, polyshrink film, and more. We also offer many services to ensure you receive the best product possible for your application.

Our team can test your insulation materials with analytical and high-voltage testing to determine the functionality of the product. If you don’t find the right solution off the shelf, we can design, engineer, and manufacture a solution that meets all of your needs.

If you are ready to see what we can create for you, contact our team today.

When looking for a partner, there are a few major factors to consider when determining which supplier is best for your needs.

Do They Carry the Products You Need?

While one supplier might have what you need right now, down the road, your needs may change. It is important to choose high voltage insulator manufacturers that carry all of the products you need to support your current goals, improve the end product, and address secondary or future-state projects. This will save you time and money trying to find a second supplier.

At Electrolock, we carry various types of high-voltage insulation materials, including:

• Mica Ground Wall Tapes
• Conductive Tapes
• Gradient Tapes
• Corona Suppression Tapes
• Crossover Insulation
• Rotor Turn Insulation
• B-Staged Tapes & Blocking Felts
• Slot Liners

On top of our high voltage insulation, we also carry various types of battery insulation, spiral wound tubing, Porex tubing, high-temperature wire and cable insulation, thermal insulation, and polyshrink film. No matter your insulation needs, we have the products needed to create a safe and functional product.

Do the High Voltage Insulator Manufacturers Serve Your Industry?

Working with someone who understands the needs, requirements, and specifications of your industry is essential. This can help them with the manufacturing process and allows your partner to help you choose the best product for your industry and your application. They will have insight into specific requirements or regulations and will have developed problem-solving methods unique to that particular sector. Allowing your insulation manufacturer to take over the responsibility of creating the right product for your industry allows you to focus on other aspects of your business.

How Much Experience Do They Have?

When your insulation manufacturer has extensive experience in their industry and in creating various products, you can rest assured that your product will be of the highest quality and meet all of your needs. With years of experience also come many customer reviews and recommendations. If you partner with a manufacturer that has decades of experience, you will have more finished products to look at and more customer reviews to see if they are a good fit for your business. A proven track record is an excellent indicator of future reliability.

What Other Services Do They Have to Offer?

While it is crucial for high voltage insulation manufacturers to provide you with the products you need to create a safe and functional product, when they offer additional services you can further optimize and streamline your production schedule. By bringing many capabilities under the same roof, you can save time and money by eliminating the need to farm out different tasks to different vendors.

At Electrolock, we offer many different services to improve and create your ideal products, including:

• Analytical Testing — Our team uses best-in-class technology to evaluate and compare your insulation materials. We test the chemical, electrical, mechanical, and thermal properties of your materials to determine which is ideal for your application.
• High Voltage Testing — We test your insulation system for dissipation factor, voltage endurance, voltage breakdown, and partial discharge.
• Solution Design — Our engineering staff believes that your insulation product should meet all of your exact needs. We will work with you to define your problem, go over budget, review data, and perform product testing to ensure the solution we create for you is exactly what you need.
• Manufacturing Services — We can convert your materials in any way you need. From slitting and rewinding to traverse splitting and spooling to laminating and more, we will help you create the ideal solution for your needs.

Electrolock is the Expert High Voltage Insulator Manufacturer You Need

Since 1957, Electrolock has been the trusted high voltage insulator manufacturer for all insulation needs. We carry numerous products from battery and thermal insulation to wire and cable insulation and high voltage insulation to meet your needs. And, if none of our in-stock products meet your specifications, our engineering team will work closely with you to create an insulation solution that fits all of your needs.

In addition to our insulation offerings, we want to help you make sure you are making the best decision for you. Our high voltage and analytical testing, solution design, and manufacturing services compare materials and make sure they are meeting all of your needs.

If you are ready to partner with the right high voltage insulator manufacturer, contact our team today.

There are various benefits to battery insulation wrap. Let’s explore them here:

Prevents Cell Overheating in Batteries

Cell overheating and thermal runaway in batteries are extremely dangerous and can cause serious harm to the device or even the individuals using the battery. Overheating can result in reduced battery performance and cause permanent damage. If the heat in the battery gets too high, it sets off a chain reaction called thermal runaway. Thermal runaway happens in a matter of seconds and the heat can cause an extremely hot fire to start that is nearly impossible to extinguish.

It is essential to prevent thermal runaway and overheating in battery cells by implementing the proper insulation materials. Battery insulation wrap can isolate the battery cell so that if it is experiencing thermal runaway it will prevent it from spreading to other cells and becoming even more out of control.

Acts as a Dielectric Barrier Between Battery Cells

Dielectric barriers prevent electrical discharges between two electrodes to discourage thermal runaway and overheating. By preventing electrical discharges from occurring between electrodes or individual cells in a battery, the chances of overheating are reduced, thus also reducing the risk of thermal runaway.

Dielectric barriers surround the individual cell batteries, physically blocking off the electrical discharges from jumping to another electrode. Again, since these barriers prevent overheating and thermal runaway, they enhance the safety of the battery and keep consumers safe.

Choose from a Variety of Battery Insulation Wrap Materials

Many different battery insulation wrap materials are available to choose from given the type of battery used, the battery’s application, and any industry requirements. While these are not all of the possibilities, some common battery insulation wrap materials include:

PET

PET is a high-strength material that is resistant to chemicals, has good dimensional stability, low moisture absorption, and good electrical insulation properties. These properties make it ideal for battery insulation, specifically as a dielectric barrier.

Polypropylene

Polypropylene, or PP, has various advantageous properties that make it a good battery insulator. It is resistant to chemicals and heat, has good tensile strength, and has low electrical conductivity.

Polyimide

Polyimide has excellent heat resistance, high tensile strength, and good electrical properties. These characteristics are consistent over a wide range of temperatures, both hot and cold, making it a great insulator.

If You Need Battery Insulation Wrap, Turn to Electrolock

For nearly 70 years, Electrolock has been engineering innovative battery insulation solutions for a wide range of industries and applications. Not only do we carry battery insulation wrap, but we also carry separator papers, pouches, and other battery insulation products.

In addition to battery insulation, Electrolock also provides high voltage insulation materials, high-temperature wire and cable insulation, thermal insulation, and more. And, if you can’t find what you need on our site, we may be able to create a custom solution for your needs.

If you want to learn more about our battery insulation wrap, contact our team today.

How Does UV Light Disinfect Surfaces?

UV light is a great disinfectant because it requires no chemicals and still eliminates microorganisms such as bacteria and viruses. The light passes through the organism, damaging its replication and protein expression processes, both of which are necessary for the survival of the organism. In just a few seconds, you have a UV-disinfected surface, gas, or liquid.

How Do the UV Reflective Porex Virtek PTFE Tubes Work?

When UV light is introduced to the reflective tube, it bounces around the chamber. If these bounces are not controlled, the effectiveness of the light will deteriorate. Using Porex Virtek PTFE tubing controls UV light bounces, which increases the effectiveness of the disinfection process.

The Porex Virtek PTFE tubing maximizes the energy used to increase the effectiveness of the disinfection. The PTFE-lined chamber recycles UV photos and the light is scattered and reflected throughout the entirety of the tube, eliminating cold spots where bacteria and viruses may survive and ensuring all surfaces are irradiated.

Applications of Porex Virtek PTFE Tubing

The high reflectivity of Porex tubing from Electrolock ensures uniform UV light distribution, increasing pathogen deactivation up to four times more than other reflective media.

Air Disinfection

Since the COVID-19 pandemic, more and more people are prioritizing clean indoor air. Businesses, educational facilities, and medical facilities are all looking for efficient, safe ways to disinfect the air in their facilities. UV disinfection can take place within HVAC systems, personal air purifiers, or self-contained air purifiers.

Water Disinfection

Clean drinking water has always been a priority, and part of that process is eliminating pathogens from the liquid. UV disinfection is a safe and effective way to accomplish this. The process can be found in home water disinfection systems, point-of-use water disinfection systems, and building water disinfection systems.

Contact Electrolock to Create Your Custom-Sized Porex Virtek PTFE Tubing

Electrolock has partnered with Porex to form UV-reflective continuous spiral-wound tubing. This tubing can be designed to work with a UV light system on ducting or piping. With a 97% average reflectance from 220nm to 400nm, less light is lost to absorption; making disinfection more efficient and effective. Electrolock’s Porex solutions also bring a host of several benefits:

• Custom sized tube matching your system requirements
• Inner lining of proprietary highly reflective PTFE with high reflectance, refractance and diffusion
• Designed as an inline tube combined with a UV light system on ducting or piping
• Eliminate hot and cold spots—Porex Virtek PTFE scatters light in all directions, spreading UV light evenly across a surface and eliminating cold spots where bacteria may survive.
• Maintain performance in high temperatures—Working temperature of Porex Virtek PTFE is 260ºC.

We can create custom-sized tubing to perfectly match your system requirements. Additionally, our experienced team can work with you to create a custom solution if needed. Whether you are looking for Porex Virtek PTFE tubing for an HVAC system, a water disinfection system, or another application, we can make sure you receive the right product at the right size.

Contact our team today to place an order, ask questions, or request a sample.

For HV coils, required insulation materials need to be able to handle the heat generated while also still performing up to electrical standards. Unlike traditional thermal insulation, which is designed to hold heat in, generator insulation tape needs to be thermally conductive—meaning it conducts or transfers heat from one side of the material to the other.

Finding the right insulation materials for your specific application—keeping in mind electrical performance and thermal conductivity— is necessary to ensure the best functionality possible, and working with a generator insulation tape supplier can ensure you find the best fit.

Need generator insulation tape? We’re here for you: Reach out to Electrolock to request a quote or ask for a sample.

Why Should You Partner with a Generator Insulation Tape Supplier?

They Have Various Insulation Tape Options

Generator insulation tape suppliers that have a wide inventory of various products and can help you find the perfect solution for your project. From power generation insulation products to high-voltage insulation tape, your supplier will be able to meet all of your needs.

Electrolock offers a variety of power generation insulation products, including, but not limited to:

• Black Irradiated Polyethylene is a film that acts as a sealant and is used as the outer layer on high-voltage coils that are processed in an asphalt autoclave
• Calmicaglas® varieties are flexible mica paper compounds that have various applications, such as motor coil insulation, low- and high-voltage machine insulation, and generator insulation
• Conductofol® varieties are mica paper products with various applications including high-voltage coil insulation and copper conductor insulation

Electrolock’s broad high-voltage insulation materials include:

• Mica ground wall tapes
• Conductive tapes
• Gradient tapes
• Corona suppression tapes
• Crossover insulation
• Rotor turn insulation
• B-staged tapes and blocking felts
• Slot liners

They Have Proven Solutions

Knowing how successful your supplier has been with past projects that are similar to yours can save you the headache of having to make constant corrections, or even finding a new tape supplier halfway through a project. Tape suppliers with experience in your industry will be able to create solutions on a tight timeline and they will be able to advise you if you ever have questions about which solutions to choose.

They Have Technical Experience and In-House Testing Capabilities

Years of experience can help you feel confident in the ability of your tape supplier to provide you with the products you need on a quick timeline, so it is important to look for a supplier that has technical experience in your industry and with your products. They should feel confident in helping you choose the right solution for you, and in their ability to deliver that solution to you.

Additionally, working with a supplier that has in-house testing capabilities can help take some burdens off of you and your team. At Electrolock, our analytical engineers take the time to test and compare insulation materials with leading-edge technology. These chemical, electrical, mechanical, and thermal property tests can help determine which product is best for your application. This will save you time and money on trying different products before finding the one that is right for you. Just as importantly, these testing capabilities are essential in validating new designs or troubleshooting problem projects.

They have Value-Adds

The best generator insulation tape suppliers can offer more services than just insulation solutions. Whether they are offering solution design to create the perfect product for your application, or manufacturing solutions that can convert your materials, they should have the services you need so you don’t have to hire another company.

At Electrolock, design solutions and manufacturing are just two of the value-added services that we offer. Our manufacturing capabilities include:

• Slitting and rewinding
• Traverse slitting and spooling
• Coating and saturation
• Laminating
• Sheeting and shearing
• Punching and rotary die-cutting
• Spiral wound tubing
• Kitting and packaging

Work with Electrolock for Your Generator Insulation Tape Needs

With more than 60 years of experience, Electrolock has extensive high-voltage insulation experience for power generation, motors, and hairpin motors for EVs and HEVs. Whether you need mica ground wall tapes, gradient tapes, or slot liners, we can match you with the best product for your specific solution.

Not only do we offer a wide range of products, but we can also help with your product testing, solution design, and manufacturing needs. We will test and compare your products for you, help you design efficient solutions, and complete manufacturing needs for you.

If you are interested in seeing what we can do for you, contact our team today.

Experienced manufacturers will have the skilled staff and the technical equipment needed to complete these tests. Gaining these answers can help you make sure you are making the right choice for your project.

What is High Voltage Testing?

High voltage testing assesses various properties of electrical insulation materials when an electric field is present, including conductivity, polarization, and dielectric losses. These tests can help identify, examine, evaluate, and compare insulation materials for various applications, helping engineers find the perfect solutions for each project.

Electrolock has various high voltage testing capabilities:

Dissipation Factor

This test measures the loss rate of energy, indicating the inefficiency of the material to contain energy as an insulation material should. The lower the dissipation factor, the more efficient the insulator.

Voltage Endurance

The Voltage Endurance test puts high electrical stress on insulation materials and measures the time-to-failure. The stress put on the insulation material is 3.76 times higher than the operative voltage, so it assesses the material’s ability to withstand high voltage.

Voltage Breakdown

This test applies voltage to an insulation material until the threshold voltage is reached and breakdown starts to occur.

Partial Discharge

Partial discharge is an electrical discharge that does not entirely bridge the gap between electrodes. This can occur in many applications when a small bit of insulation material cannot cope with the electrical stress of a high-voltage environment.

What are the Benefits of High Voltage Testing on Insulation Materials?

There are various benefits of testing voltage on insulation materials. From product design to safety, these tests are important for many electrical applications. These benefits include:

• After seeing the results of the test, engineers can design and develop more efficient products for your insulation systems
• Increases the quality of the insulation product and decreases the likelihood of electrical shocks or other accidents after implementation
• Avoid loss of production by preventing equipment and machine breakdowns

What Types of Tests are Run?

Various tests are run during high voltage testing, each assessing a critical function of the insulation material. At Electrolock, we use the following tests to determine the properties of insulation materials and find the best solution for our clients:

Hipotronics Hipot Tester

This tester determines the insulation material’s ability to withstand voltage by applying an electrical current. The hipotronics hipot tester helps to ensure the insulation is effective at withstanding high voltage.

Megohm Bridge

The megohm bridge measures the opposition to the flow of an electric current—or high resistance. The higher this resistance is, the better and more effective the insulator.

Capacitance Bridge

This test is used to measure a capacitor’s unknown capacitance, or ability to store an electric charge. The higher this value is, the better the insulator, as they produce a layer of opposite charge, increasing capacitance.

Dissipation Factor Testing

This test uses electricity to define and determine the overall condition of the insulation material. Many times, the dissipation factor is used to determine the quality of insulation.

Electrolock Has Everything Needed to Test Your Insulation Material

At Electrolock, we want to supply our clients with the highest quality insulation materials for their applications. Whether that is spiral wound tubing or battery insulation, we have solutions for all of your electrical insulation needs.

And, if you can’t find what you need out of our inventory, or you are unsure of which products will work for you, our team of engineers can give you a hand. We offer testing and solution design services, so we can help you determine what is right for you. From comparing insulation materials to testing their properties to developing new products, our experienced team is here to help.

Contact our team today to see what we can do for you.

Materials Used as Dielectric Barriers

Mica

Mica is a very poor conductor of electricity, and with a dielectric strength of 2000 volts per millimeter, it is very good at withstanding high voltages. It forms in thin sheets, making it lightweight, flexible, durable, and easy to cut to size. This material is also able to withstand extremely high temperatures, so it will not melt or break down if exposed to a wire or battery that is overheating.

Polyimide

Polyimide is a popular dielectric material due to its thermal stability, impressive mechanical properties, and high electrical insulation properties. Generally, it is used to keep electronic wires from igniting or succumbing to low or high temperatures. It can also be reinforced with fiberglass to make it more rigid, depending on the application.

Teflon® (PTFE)

Teflon, or PTFE, is a chemically resistant polymer that can tolerate an extremely wide range of temperatures—from -400℉ to 500℉. Its high dielectric strength makes it a good insulator for batteries or wires and cables, and it is extremely durable.

PET

PET is a high-strength polymer with low moisture absorption. It has good dielectric properties, not allowing electric current to pass through it, making it a great choice for wire coatings, battery cell wrappers, and other dielectric barrier applications.

Polypropylene

This flexible polymer is resistant to chemicals and heat and has impressive impact tolerance. Polypropylene does not conduct electricity well, and since it can also handle high temperatures, it is a common choice for dielectric barriers.

Fiberglass

Fiberglass is non-corrosive, heat resistant, and durable. It can maintain its structure under mechanical stress and extreme temperatures. Fiberglass is also non-conductive, making it a good choice for insulation applications as well as dielectric barriers.

Applications of Dielectric Barriers

Wire and Cable Insulating Tapes

Insulating tapes for wires and cables are generally made from mica, polyimide, or Teflon/PTFE. Primarily, these tapes are used for fire survival for control and power cables, mass transit, aircraft, oil wells, thermocouples, appliance wires, and shipboard cables.

At Electrolock Inc., there are various insulation materials for wires and cables, including:

• Polyimide Products: Apical and Kapton tapes
• Teflon Products: FEP, PFA, PTFE, Sintered, Tensilized, UnSintered tapes
• Mica Products: Nomex® and Pyrodox products

Battery Insulation

Battery insulation is crucial to the health of the battery and the safety of those using it. These products are generally made from polyimide, PET, polypropylene, fiberglass, PTFE, and mica. Various products can be chosen based on the type of battery, the battery’s application, and cost. Regardless, all of these products can prevent thermal runaway and overheating from cell to cell or for individual cells.

There are numerous battery-insulating products available at Electrolock Inc. From cell wrappers to heat shrink spiral wound tubing, we have it all:

• Polyimide Products: Cell Wrappers, Jelly Roll Wrap, and Polyimide Laminates
• PET Products: Cell Wrappers, Die Cut Top & Bottom Cell Insulator, Jelly Roll Wrap, and PET Layflat Tubes
• Polypropylene Products: Cell Wrappers and Jelly Roll Wrap
• Fiberglass Products: CraneGlas®, Die Cut Top & Bottom Cell Insulator, Go-Therm Thermal Runaway Barrier, and Pyrodox with fiberglass backing,
• PTFE Products: Die Cut Top & Bottom Cell Insulator
• Mica Products: Pyrel-Therm and Pyrodox

Turn to Electrolock For All of Your Dielectric Barrier Needs

Preventing overheating, thermal runaway, and potential electric shock is critical in all applications. Whether it is in batteries or wire and cable applications, having the proper dielectric barriers is paramount.

At Electrolock Inc. we understand the importance of implementing the right type of insulation and we will work with you to understand your application and find the right product for you. Our team can also perform analytical and high-voltage testing on insulation materials so we can be sure the product chosen is right for you. If you can’t find exactly what you need, we offer custom solution design to develop an entirely new product that will meet every one of your needs.

Contact our team to find the right solution for your application.

How Does Die Cutting Work?

The process of die-cutting is fairly straightforward. A metal die is created in the desired shape and is then pressed against a hardened anvil roll to cut the shape out of the material passing through the two components. This creates neat and precise outlines by cutting, forming, and shearing products from sheets or rolls of material.

The created die can also be reused, meaning the desired shape and product can be replicated as often as needed. Die-cutting is the best method for high-volume runs that require precision and accuracy.

Die-Cutting Creates Custom Electrical Insulation and Cell Wrapping Solutions

Die-cutting creates custom insulation solutions by puncturing electrical insulation materials and cell wrapping. Materials such as mica tape, wire and cable insulation tape, silica tape, and cell wrappers made of polyimide, PET, and polypropylene are just some of the insulation options that can undergo die-cutting.

Advantages of Die-Cut Solutions for Electrical Insulation and Cell Wrapping

There are various benefits to choosing die-cut solutions rather than stock materials. From having a customized product you know will fit to reducing waste, die-cut solutions are worth considering.

Uniformity and Customization

Many complex shapes are found in electrical applications, especially in battery insulation. Die-cutting electrical insulation materials create the exact shape and size needed for the application while also being able to maintain uniformity throughout production. This means all of your products will have the same dimensions and look the exact same throughout the entirety of their manufacturing.

Reproducibility

The dies used in this manufacturing process can be used repeatedly. So, no matter how many products you need or how many rounds of manufacturing you need to do, your die will still be able to reproduce the same product.

Reduced Waste

When using die-cutting to produce customized electrical insulation and cell wrappers, there is very little waste produced. Creating custom products for specific applications means they will fit without needing to be altered, producing less waste than if you were to use a stock product. Additionally, the actual process of die-cutting doesn’t produce much waste. Since the die can be reused and there is very little product left over, excess material or wasted dies are rare.

Easily Tackle Complex Designs

Rather than having to hand cut your electrical insulation or cell wrapping, dies can be created in nearly any shape, meaning even your most complex designs can be created through die-cutting. This will save you time and money in the long run and make it easier to produce these complex products repeatedly.

Trust Electrolock with Your Die-Cut Solutions for Electrical Insulation and Cell Wrapping

Not only does Electrolock have all of the materials and products you could possibly need for your electrical insulation projects, but we also offer various services to ensure your product is the best possible fit for your needs. Whether you need analytical and high-voltage testing, custom solution designs, or manufacturing services, we have you covered.

When you work with Electrolock, you access our leading-edge technology to identify, examine, evaluate, and compare your insulation materials. Our team can even help you develop more efficient designs with our high-voltage lab and solution design services. And if you need a customized design, our manufacturing services can convert your materials however you need. From slitting and rewinding to punching and rotary die-cutting, Electrolock has all of the manufacturing capabilities to create bespoke insulation solutions.

Contact our team today to see what we can do for you.

PET Insulation Materials

PET Layflat Tubes

PET layflat tubes are thin-walled, heat-shrinkable tubing or sleaving that provide physical strength and dielectric protection for electrical applications. Generally, this PET insulation material is implemented as a wear-resistant insulating cover for various products. And, since it is available in a variety of diameters, widths, and lengths, it can be designed to suit any necessary application or process requirements.

The most common application of PET layflat tubes is providing outside battery cell protection. These layflat tubes ensure that each battery cell is contained in its own module, protecting them from other cells. Outside cell protection is critical to the safety and functionality of the battery and is particularly important in electric vehicle (EV) batteries. Requiring extremely high amounts of energy to function, EVs use high-voltage batteries to store power. PET layflat tubes are used to protect each cell in these high-voltage batteries, allowing the batteries to continue to function properly.

PET Spiral Wound Tubing

Expandable PET spiral wound tubing is designed to firmly hold wires while still allowing flexibility and easy access. This PET insulation material guards against abrasion and tearing while providing chemical and thermal protection. It can also add tensile strength, tear strength, and thermal conductivity to applications.

PET spiral wound tubing is typically in applications that need to meet electrical, thermal, mechanical, and chemical performance requirements. These instances include battery sleeves, wire connection insulation, and slot liners for EV motors.

Non-Woven PET Thermal Insulation Products

PET non-woven thermal insulation provides excellent strength, good air permeability, tensile strength, and tear resistance to various electrical applications. Non-woven PET insulation applications include electrical insulation, mica tape reinforcement, electrical laminated products, electric motor coil wrapping, and various cable insulation.

Needled Felt PET Thermal Insulation Products

Needled felt PET is characterized by its resistance to heat, tensile strength, anti-erosion properties, and exceptional electrical insulation. This PET insulation product is found in air conditioners, refrigerators, microwaves, and dishwashers as thermal insulation.

PET Polyshrink Film

PET polyshrink film is designed to apply the correct compaction force to electrical applications. It is designed to optimize compaction forces during the curing cycle of high-voltage coils and electrical composites. PET polyshrink film is largely used in the compaction of high-voltage coils, resin-rich coils, and wiring systems.

Electrolock Has All of the PET Insulation Materials for Your Project

For more than 60 years, Electrolock has been providing various types of electrical insulation products to our customers. From high-voltage insulation materials to battery insulation to Porex® tubing, Electrolock has the products and the expertise to match you with the right product for your application.

Our insulation materials have a wide range of applications, including battery insulation, coil wrapping, wire insulation, and so much more. When you work with us, we will help you determine the best product for your requirements and we will customize our products for you.

If you are interested in learning more about our products or services, or if you are ready to get started, contact us today.

There are many materials that you can choose from depending on your needs. From shielding to flame and dielectric barriers to separators, it is important to understand which materials are right for your application.

Need an Insulation System? We’re here to help: Reach out to Electrolock to learn how we design tailored insulation solutions, request a quote, or ask for a sample.

Types of High-Temperature Electrical Insulation Materials

Polyimide

This high-temperature polymer is a great choice for electrical insulation applications due to its thermal stability, chemical resistance, and mechanical durability. Polyimide is able to withstand temperatures greater than 500°C or 932°F, making it a great polymer for insulation in applications where temperatures can be volatile.

Electrolock carries both Apical® and Kapton® products, which fall under the polyimide umbrella. Both have strong thermal, electrical, and chemical properties that are great for insulating motor generators, wires, and cables.

Teflon® or PTFE

PTFE, more commonly known as Teflon, is a synthetic polymer made from carbon and fluorine bonds. It is one of the most popular insulating materials due to its ability to withstand extreme temperatures up to 260°C or 500°F. With its dielectric properties and chemical resistance, it is used widely in wire insulation in the automotive, construction, and aerospace industries. Electrolock carries various types of Teflon, including:

• PFA is one of the strongest, most durable forms of Teflon, being able to withstand the hottest temperatures of the PTFEs
• Sintered PTFE has a high elongation and is resistant to weathering, making it ideal for wrapping wires and cables
• Tensilized PTFE provides greater tensile strength, meaning it can handle a lot of stress in the form of force, and is used to wrap electrical transformers and wires
• UnSintered PTFE is exclusively used for wrapping wire and cables due to its excellent dielectric properties

Nomex® Mica

With high dielectric strength, flexibility, and resilience, this material is an excellent insulator for electrical equipment. There are various types of Nomex tape that Electrolock supplies, such as:

• Nomex 410 is used in a majority of electrical equipment and is the original form of Nomex®
• Nomex 411 has high bulk and conformability, which makes it ideal for use as motor phase insulation and transformer coil filler
• Nomex 418 has a high voltage tolerance, allowing it to be used in high-voltage applications, such as motor conductor wrap, coil wrap, transformer ground insulation, and layer insulation

Pyrodox® Mica

Pyrodox is a heat-treated mica tape that is made to withstand electrical and thermal overloads and high-moisture conditions. Due to its properties, it can be used in various applications, such as fire survival for power cables, transit, oil, thermocouples, and appliance wiring. A few of the Pyrodox Mica tapes available through Electrolock are:

• Pyrodox GP is a phlogopite mica tape that is made of halogen-free silicone binder and non-alkaline fiberglass backing
• Pyrodox GM is a calcined muscovite mica tape that has similar components and properties as Pyrodox GP
• Pyrodox PEP is a heat-treated phlogopite mica tape with a halogen-free silicone binder and polyethylene backing
• Pyrodox SG is a synthetic mica tape with a halogen-free silicone binder and non-alkaline fiberglass backing
• Pyrodox SEP is a synthetic mica tape made with a halogen-free silicone binder and polyethylene backing
• Pyrodox PET is a phlogopite mica tape with a halogen-free silicone binder and polyester backing

Partner with Electrolock to Discover the Right High-Temperature Electrical Insulation Materials for You

For more than 60 years, Electrolock has been creating insulation products for high-temperature electrical applications, batteries, high-voltage applications, and thermal runaway applications. Our goal is to create safe and effective insulation materials that maintain the integrity of your product and keep the electrical properties of the wire intact.

Your high-temperature electrical application is unique, which is why our team of engineers will work closely with you to create a custom insulation solution that will fit your exact needs. We offer various raw materials and products so we can quickly design, manufacture, and convert your insulation products to get them to you quickly.

Contact our team today to see what solutions we can create for you, or to talk to one of our experts about your specific needs.

Mica tape is an essential component in various industries as it is prized for its performance in many applications including electrical insulation, fire-resistant applications, and thermal management. Its unique properties make it a popular choice for insulating cables, wires, and other electrical components. However, choosing the right mica tape supplier is crucial to ensure the quality, reliability, and performance of your products.

Here, we’ll examine the key factors to consider when selecting a mica tape supplier and how Electrolock is positioned to be an ideal provider of this important insulating material.

Need an Insulation System? We’re here to help: Reach out to Electrolock to learn how we design tailored insulation solutions, request a quote, or ask for a sample.

Important Considerations for Your Next Mica Tape Supplier

Quality and Certification

The first and most critical factor to look for in a mica tape supplier is the quality of their products. High-quality mica tape ensures better performance, longevity, and safety in the end application. Ensure that the supplier complies with relevant international standards, such as ISO 9001, which demonstrate their commitment to quality management and environmental responsibility.

Technical Expertise and Support

Choosing a supplier with a strong technical background is invaluable, especially when dealing with complex applications that require specific mica tape characteristics. A knowledgeable supplier will be able to guide you in selecting the most suitable option for your specific needs. They should have experienced engineers and technical experts who can answer your questions, provide recommendations, and offer tailored solutions.

Customization Options

Every application is unique, and a reliable mica tape supplier should offer customization options to meet your specific requirements. Whether you need a particular thickness, width, or adhesive type, a supplier willing to customize their mica tape products will ensure that you receive the most suitable solution for your application.

Research and Development

A mica tape supplier that invests in research and development is more likely to provide innovative solutions and stay ahead of industry trends. New advancements in mica tape technology can lead to improved performance, efficiency, and cost-effectiveness in your applications. Therefore, choosing a supplier that prioritizes research and development, and has in-house testing capabilities to validate results, will keep you at the forefront of the industry.

Good For More Than Tape: Mica Plate has become a popular choice to provide robust thermal runaway protection for EV applications. Learn more here.

Electrolock: A Trusted Mica Tape Supplier

Electrolock has been engineering solutions for the high-voltage electrical, battery, and thermal insulation industries since 1957. Over that time our focus has remained firmly on creating unique and tailored solutions to service the most demanding requests. We have the distributor relationships and engineering experience to find the right application solution for you. Electrolock is proud of its relationship with Isovolta, a premium manufacturer of mica tape for medium and high-voltage applications.

Selecting the right mica tape supplier is a critical step in ensuring the success of your projects and the quality of your end products. Prioritize factors such as product quality, technical expertise, and customization options when evaluating potential suppliers. By choosing a reputable supplier with a commitment to quality and customer support, you can build a strong partnership that will positively impact your business and enhance your product offerings.

Connect with Electrolock today to schedule a one-on-one evaluation regarding mica tape, other custom insulation needs, and application specifics.

Thermal runaway events are particularly dangerous for Li-ion batteries, given the notorious nature of combating fires involving them. Knowing what thermal runaway is, what causes it, and how to prevent it can make your batteries safer and more efficient. It also gives insight into the considerations needed for a thermal runaway barrier.

What Causes Thermal Runaway?

Many things can cause or contribute to thermal runaway, including internal and external conditions that aren’t conducive to the battery’s function. More specific causes include:

Internal Short Circuiting

When the separator, or the part of the battery that separates the cathode and anode electrodes, is damaged, the electric current can flow through a shorter, unintended pathway causing the cell to heat uncontrollably.

Overcharging

Incompatibility between the cell and the charger or a poorly designed battery management system (BMS) can cause overcharging. The BMS technology is responsible for overseeing a battery pack, including monitoring the battery’s performance, providing protection, and reporting operational status to external devices. When the BMS is poorly designed or damaged from overcharging, these oversights aren’t produced making it difficult to catch battery malfunction before thermal runaway occurs.

Over Discharges Followed by a Charge

Discharging, or draining, is the process of the battery losing voltage or energy. When a cell or battery is discharged below the manufacturer-recommended voltage threshold, the battery’s chemicals are changed. While charging generally replenishes voltage and restores chemical balances, if the battery discharges repeatedly, or over discharges, and is then charged, the battery and its chemicals can become volatile, leading to thermal runaway.

External Short Circuit

When a battery cell discharges at a fast rate in large currents, rapid heat generation occurs. This can be brought on when the battery terminals come into contact with metal objects, causing sparks or heating to occur, leading to thermal runaway.

High- and Low-Temperature Environments

If a battery isn’t properly insulated, high and low temperatures in the external environment can lead to overheating within the battery, fueling thermal runaway.

How to Prevent Thermal Runaway

Thermal runaway can be prevented in a few ways. Making sure you are keeping track of your battery’s charging and health, storing your batteries at the proper temperatures, and making sure your battery is fit with a proper battery thermal runaway insulation are the best ways to keep your battery safe and functioning properly. Manufacturers should communicate best practices to their customers about how to care for and manage their battery packs and rechargeable components.

Choosing the Right Battery Thermal Runaway Barrier and Insulation with Electrolock

Go-Therm Thermal Runaway Barrier

Electrolock’s Go-Therm Thermal Runaway Barrier products offer unmatched battery pack protection from the ejecta and flame that can be caused by thermal runaway. This flexible insulation option can be used as a thermal runaway barrier between prismatic cells in a module and can be fabricated to size for your specific needs.

There are two options for the Go-Therm Thermal Runaway Barrier. The Go-Therm 150 is a glass-on-one-side silicone laminate thermal runway barrier that is designed to line the interior of the battery case. On the other hand, the Go-Therm 315 is a dual-sided fiberglass-backed laminate for the interior lining of the battery case or module-to-module barrier protection.

Pyrel-Therm

Electrolock has various Pyrel-Therm products, including Pyrel-Therm EIG 1000, Pyrel-Therm ES 1100, Pyrel-Therm RMC Mica Heat Shield, and Pyrel-Therm TS 800C.

The Pyrel-Therm EIG 1000 and Pyrel-Therm ES 1100 are thin, high-temperature insulation options that are designed to meet extreme heat environments. Both products provide excellent thermal resistance, low shrinkage, and low thermal conductivity at high temperatures. Pyrel-Therm EIG 1000 insulation has excellent compression resistance and is available in widths up to 1016mm while Pyrel-Therm ES 1100 has excellent mechanical properties and is available in widths up to 1220mm.

Pyrel-Therm RMC Mica Heat Shield is designed to meet the demands of extreme heat environments with its low heat transfer abilities. It is also an effective dielectric and gas barrier. Available in master rolls up to 1 meter in width, it can be customized with slits or punched parts. Thicker forms of mica, including mica plate, are becoming increasingly popular as a robust insulation solution for heavier EVs.

The Pyrel-Therm TS 800C is Electrolock’s thin, semi-flexible sheet used in applications where high temperatures must be tolerated and low thermal conductivity is required. With its superior resistance to high heat and flames, it provides an excellent heat shield in electronics and military applications.

Electrolock is Your Partner in Finding an Ideal Thermal Runaway Barrier

Since 1957, Electrolock has been providing premiere insulation products for various kinds of batteries. We are continuously focused on creating unique and innovative solutions for any high-voltage electrical, battery, or thermal insulation needs. Our wide range of products allows us to choose the right solution for your application.

The thermal runaway insulation materials chosen for your application should meet all of your needs and fit your application. Electrolock’s team will work with you to test materials to determine which works best for you and design the right solution. Contact Electrolock today for your custom thermal runaway barrier insulation solution.

The world today runs on batteries, of many types and styles. Larger battery packs power electric vehicles (EVs), smaller lithium-ion or lithium polymer batteries fuel our cellphones and tablets and even ‘traditional’ batteries empower a plethora of hand-held devices. However, each of these use cases needs battery insulation material to help protect batteries from external factors, maintain optimal operating conditions, and prevent malfunction.

The variety in the type of battery insulation material is needed as various industries and applications have different requirements for battery protection. Today, we’re examining some of the most common materials used for such purposes and offering examples of the types of products implementing those materials for battery insulation purposes.

Need battery insulation solutions? We’re here to help: Reach out to Electrolock to learn how we design tailored insulation solutions, request a quote, or ask for a sample.

Reviewing Types of Battery Insulation Material

The following list provides a general overview of commonly used battery insulation materials. It’s important to note two things. First, this list is non-exhaustive and many of the materials can be configured into rigid, flexible, or semi-flexible solutions. Second, the specific insulation materials used in batteries can vary depending on the type of battery, its intended application, and industry requirements.

Polyester (PET) — PET offers good electrical insulation properties, high tensile strength, chemical resistance, and dimensional stability. It is often used as a separator material in batteries to prevent short circuits between the positive and negative electrodes. PET can also be used as a film or coating material for battery casings.

Polypropylene (PP) — PP is another popular choice for battery insulation due to its low electrical conductivity, good chemical resistance, and high-temperature tolerance. It is often used in battery separators.

Fiberglass — A composite made of fine glass fibers, this material helps as a thermal and electrical insulation material due to its high strength, resistance to chemical corrosion, and low thermal conductivity.

Mica — A natural mineral with excellent electrical and thermal insulating properties, Mica is often used as a separator material in batteries to prevent thermal runaway and improve safety.

Polytetrafluoroethylene (PTFE) — This non-stick material is known for its excellent electrical insulation properties, chemical resistance, and high-temperature tolerance. It is used in battery applications where chemical compatibility and electrical insulation are crucial.

Battery Insulation Material Solutions

The preceding list of materials can be used exclusively or combined to create ideal insulation solutions for battery applications. At Electrolock, we have expertise across a wide and diverse range of materials and use that knowledge to create battery insulation solutions that answer any challenge you face. Here’s a snapshot of several solutions we offer.

Heat Shrink Spiral Wound Tubes

Heat shrink polyester sleeving is used as a protective cover against abrasive or chemically harsh environments while also offering high dielectric protection, good tensile strength, and excellent chemical resistance. This sleeving will shrink in length and diameter when subjected to oven temperatures above 300°F or using a heat gun or similar heating device.

PET Layflat Tubing 740 HS

This lineal seal tubing comes as heat shrink sleeves with an extremely thin wall that provides both dielectric protection and physical toughness. The 740 HS is composed of a one-side, anti-static treated modified polyester (PET) film that is clear in color but can be printed on or colored. Formed into tubing, 740 heat shrink sleeves shrink quickly — roughly in 10 seconds at 100°C — and uniformly around cylindrical shapes.

Die-Cut Top & Bottom Cell Insulator

For inside the cell, dielectric barrier insulation, die-cut components are available in a variety of materials, including fiberglass, PTFE, PP, or PP. These are custom punched according to the specifics of the application.

Jelly Roll Wrap

This is a custom-designed dielectric barrier that fits between the jelly roll and the can of the battery. PET and PP, as well as polyimide, are commonly used here and often combined with a chemically-compatible adhesive for application.

For the jelly roll wrap and die-cut insulators, interested parties should contact Electrolock directly about technical specifications, availability, or samples.

What About Mica? Discover the strength of mica plate battery insulation and how it’s become a robust solution for EV applications.

Need Battery Insulation Material Expertise? Trust Electrolock

Every battery pack is different as each is designed specifically for its intended application. Therefore, each battery pack has different requirements for insulation placement and performance. This is where Electrolock can help. Finding the right materials for dielectric protection and thermal runaway and supplying the materials so that they fit in the limited insulation space in the pack is our specialty. Electrolock engineers try to understand all of these requirements and then submit the best material options for testing.

We have a vast library of material options and are not limited to any specific material choice. Once the customer approves materials, we provide the finished parts for use in the production of the packs.

Electrolock has produced premier custom insulation products, including the use of many spiral wound tubing materials, for the high voltage electrical, thermal insulation, and battery industries for more than 60 years. We have deep experience in working with any material to solve insulation challenges.

Connect with Electrolock today to schedule a one-on-one evaluation regarding custom insulation needs and application specifics.

Motor insulation solutions remain a critical component in essential industries, including the construction of high voltage power generating coils and the manufacturing of various hairpin motors serving the EV and HEV markets. Insulation systems are particularly important when it comes to motor and generator coils, resource-heavy investments that require high-quality protection to ensure their performance and enhance their operable lifespan.

When looking for electrical insulation solutions, whether for a new coil design or to improve the performance of an existing product, it’s critical to consider what the right partner should bring to the table. You need an insulation provider that understands the time demands the industry operates under, has a proven track record of delivering high-quality products, forms difference-making vendor relationships, and has the expertise to work through problems to find tailored solutions to your specific needs.

When seeking motor insulation solutions, you need a partner you can trust. Electrolock has decades of experience in designing, manufacturing, and testing insulation products covering a wide range of applications. We take pride in going beyond what’s expected to deliver the results our customers need. Let’s go over some of the elements many of our long-term partners have relied on for their critical electrical insulation projects.

Need an Insulation System? We’re here to help: Reach out to Electrolock to learn how we design tailored insulation solutions, request a quote, or ask for a sample.

Working with You for Motor Insulation Solutions

At Electrolock, we’ve worked hard to build relationships with our customers based on a set of core beliefs, technical expertise, and proven results.

We Provide Expert Motor Insulation Solutions

Because Electrolock covers every aspect of motor and high voltage insulation, it can address all the major processes used in constructing coils — and find the right insulation system and products to ensure their operation.

• Vacuum Pressure Impregnation (VPI) — This process requires ‘dry’ tape (with no resin) for completion.
• Resin-Rich — Conversely this process needs ‘loaded’ tape for the hydrostatic pressure application.
• Dip and Bake — Typically this is the most economical approach for medium voltage coil insulations. It offers a quick way to encapsulate the insulation system with a varnish to protect and provide some level of additional insulation protection.

Electrolock also provides expertise in corona suppression tapes and many ancillary materials that are important to motor insulation. Beyond this one segment, Electrolock also covers solutions for battery insulation, thermal runaway, spiral wound tubing, and many more applications. Electrolock is capable of finding the bespoke fix to your engineering challenge.

Exceptional Service

Beyond expertise in designing and providing insulation systems, and testing their effectiveness, Electrolock also works with customers to provide high-value additional services. This includes assistance in inventory management. We have Just-In-Time capabilities, even rush shipments when needed, and have developed applications to help our customers better manage a wide variety of Electrolock SKUs to improve lead times and reduce shortages.

These services, combined with our range of manufacturing capabilities and technical expertise, help Electrolock deliver timely, needle-moving solutions. Time is of the essence for motor and high-voltage coil manufacturers and Electrolock allows them to save on that precious resource and positively impact the bottom line.

How it Looks in Practice

Consider this scenario: A large high-voltage coil manufacturer is nearing the completion of a critical project, complete with many custom specifications. It represents a significant investment. The bars are built and installed, and all the other components are in place, but one element is still missing. The company originally contracted to provide a key component in the insulation solution — a particular spec of mica tape — has had difficulty finding the right solution for the project. The whole endeavor is paused.

Enter Electrolock. We’re familiar with the needed component, know it inside and out, have experience in its application, and have it (or an equivalent) on-site. Roped into the project in the evening, Electrolock can tackle the specifics and get a solution out the door the next day. With each day representing a significant cost, Electrolock can deliver timely mission-critical solutions with our expertise and experience.

Need Tape, not Tubing? Learn more about Electrolock’s polyester heat shrink tape options that provide compression and a clean release.

Trust Electrolock for Motor Insulation Solutions

Electrolock has been engineering solutions for the high-voltage electrical, battery, and thermal insulation industries since 1957. Our focus remains focused on creating unique and tailored solutions to service the most demanding requests. We have the distributor relationships and engineering experience to find the right application solution for you.

Connect with Electrolock today to schedule a one-on-one evaluation regarding custom insulation needs and application specifics.

Heat shrink tubing is often used as a release layer on tooling — such as mandrels, and inflatable bladders — to allow products and parts to freely be removed from tooling after curing. Heat shrink tubing is applied to the tooling before the composite matrix layup or prepreg is added to ensure the free release and is seen as an ideal alternative to more traditional (and manually intensive) options of hand-taping or adhesive release tapes.

However, beyond use as a release layer, heat shrink tubing can also be implemented as a wear-resistant or insulating cover for different products and applications. Different materials should be used depending on the application and PET layflat tubing matches perfectly with the needs presented in battery insulation.

Electrolock has decades of experience in providing the support you need to solve your battery insulation problems — both inside and outside the cell. Let’s examine two such solutions featuring PET layflat tubing.

We Provide Solutions: In this video, learn how Electrolock collaborates with customers to find the customized solutions they need to move the needle for their business.

PET Layflat Tubing for Outside the Cell Protection

Outside the cell protection, like battery insulation sleeving, is critical for the continued safe and ideal operation of batteries. Such insulation ensures each cell contained in a module is protected from other cells in that enclosed environment.

This is a crucial element for many industries, but outside the cell protection and insulation are especially relevant for Electric Vehicles (EVs). EVs need vast amounts of energy to operate — stored in high-voltage batteries that require perfect electrical insulation to function correctly. EV batteries feature three distinct units contained within one another — individual cells, groups of cells contained within a module, and the battery pack. This means dielectric protection outside of each cell is of the utmost importance to safety and efficiency.

Strong Combination of Material and Fabrication

PET layflat tubing is a heat-shrink solution that fits perfectly with this specific industry and other battery sleeving applications. Part of the reason for this is material.

Polyester and PET films and tubing offer high dielectric strength, ensuring a proper protective barrier between the power-containing cell and its environment. PET tubing also can be made with an extremely thin wall, has a higher shrink percentage than similar materials (such as FEP), and can be heat activated to begin shrinking at around 60°C (140°F).

Where shrink tape is designed to wrap around a composite part before the curing process, layflat tubing is designed to shrink around tooling (as mentioned earlier) or post-cured parts (like batteries) to provide protection. This leads to several advantages over a tape solution:

Faster sleeving — With PET layflat tubing, sleeving tools is a much simpler process and sleeving individual parts can be automated — with the removal of hand application and removal processes.

Prevents FOD — Foreign object debris is common with hand-taping and can negatively affect performance. With PET layflat tubing, sleeving is consistent without the risk of contaminants finding their way onto the tool or part surface.

Reduces Mark-Off — Ensuring a clean, consistent surface finish is critical, but with taped-on release liners or other adhesive products, the results can be anything but. Because PET layflat tubing only has a small seam down its length (lineal sealing), the impact on the surface finish is drastically reduced or eliminated altogether.

Two Electrolock Examples of PET Layflat Tubing

Electrolock provides battery insulation solutions that are available in a variety of diameters and lengths. Our solutions can be designed to suit machine and process requirements.

PET Layflat Tubing 740 HS

This lineal seal tubing comes as heat shrink sleeves with an extremely thin wall that provides both dielectric protection and physical toughness. 740 HS tubing is composed of a one-side, anti-static treated modified polyester (PET) film that is clear in color but can be printed on or colored. Formed into tubing, 740 heat shrink sleeves shrink quickly — roughly in 10 seconds at 100°C — and uniformly around cylindrical shapes.

PET Layflat Tubing 800 FRC

Another lineal seal tubing solution, 800 FRC heat shrink sleeves also have an extremely thin wall that offers dielectric protection and physical toughness. This tubing differs from the 740 HS version in that it features a one-side, anti-static treated modified PVC film. But, just like the 740 HS, the 800 FRC is clear but can be printed or colored and shrinks quickly — again in 10 seconds at 100°C — and uniformly around multiple shapes.

Need Tape, not Tubing? Learn more about Electrolock’s polyester heat shrink tape options that provide compression and a clean release.

Learn More from our Experts in High Voltage Insulation Testing

Electrolock has been engineering solutions for the high-voltage electrical, battery, and thermal insulation industries since 1957. Our focus remains focused on creating unique and tailored solutions to service the most demanding requests. We have distributor relationships and engineering experience to find the right application solution for you.

Connect with Electrolock today to schedule a one-on-one evaluation regarding custom insulation needs and application specifics.

No coil manufacturer will make the decision to alter the insulation systems involved in coil construction lightly. Perhaps a coil needs to be downsized to fit into a smaller space. Maybe there have been quality issues or premature failures. It’s possible the capabilities of the design need to be improved.

In short, there has to be a compelling reason to make the change because it’s not easy to implement. It’s an expensive and time-consuming process — taking months or even a year — to properly design and validate a new high voltage coil and the insulation systems that make it work. It’s a significant investment for any high voltage power generation or motor manufacturer.

Examine the Data

When the material needed for the new insulation system or the process of constructing the coil changes, Electrolock can help in evaluating the new elements or finding optimal solutions.

Electrolock has decades of experience in assisting in the verification of new insulation systems, finding answers, and confirming proposed changes. From our Hiram, Ohio facility and in accordance with Institute of Electrical and Electronics Engineers (IEEE) standards and procedures, we perform high voltage insulation testing that helps manufacturers proceed with proper care and scrutiny. So, whether a company is exploring mica groundwall changes, turn or strand insulations, or changes to the conductive or gradient tapes used, Electrolock can help provide the additional testing data needed to guide the decision-making process.

Let’s examine a few of the many types of high voltage insulation testing Electrolock provides.

Need More Testing Assistance?: Electrolock performs analytical tests on the chemical, electrical, mechanical, and thermal properties of materials to determine which will work best for your application.

High Voltage Insulation Testing Essentials

Thorough testing of new materials and processes is the goal of many of the high voltage coil manufacturers, from seeing just how much voltage a generator can handle to how long it can last. Electrolock’s high-voltage lab is outfitted with the equipment required to conduct these tests and manned by an engineering team with years of analytical experience. Below are outlines of some of the tests Electrolock provides to measure and grade the performance of high voltage coils.

High Voltage Breakdown

This test determines just how much a high voltage coil can take and is generally run until failure — voltage is increased until a breakdown occurs.

The minimum requirement for a high voltage coil is typically twice the rated voltage, plus 1,000 volts. With a coil designed for 13,600 volts, for example, the minimum voltage level acceptable before breakdown would be 28,200 (13,600 x2, plus 1,000). Well-made coils should easily surpass this minimum requirement. For instance, the 13,600-volt example above wouldn’t typically see a breakdown until the 60,000-volt threshold. Electrolock is equipped to conduct in-house testing up to 100,000 volts.

Dissipation Factor (with Tip Up)

This test measures the dissipation factor of a coil — the Tangent of the Loss Angle — and is commonly conducted alongside or concurrently with a high voltage endurance test.

Usual practices determine that the dissipation factor is measured at 25% of the line to neutral voltage (below the partial discharge inception voltage); the expected dissipation factor is expected to be less than 1%. The change in dissipation factor between this initial test voltage and the measurement conducted AT the line to neutral voltage of the coil — this is Tip Up — is expected to be less than 0.5%.

Sometimes customers ask for dissipation factors to be run at 125% of the line to neutral voltage or at the operating temperature of the motor or generator. At 25%, this team offers a good examination of the resin system, mica, and other components used in the coil’s construction. The data provided by the Tip Up provides information on how well the coil is made; Higher percentages (the lack of a flatter curve) here could indicate the presence of voids or wrinkles, or even delamination, in the ground wall.

High Voltage Endurance

This exponential stress test is used to see if a high voltage coil is likely to meet the proposed life of its warranty when implemented in the field. The test is typically conducted along with the dissipation factor test.

In this examination, the coil is run at approximately 3.82 times the line to neutral voltage for 400 hours — or 4.46 times the line to neutral voltage for 250 hours. Increasing the voltage stress on the coil to a level well above its expected use accelerates the degradation of the coil under partial discharge. Voltage endurance testing is an important qualification test for high voltage coils.

Partial Discharge Measurements

Partial discharge testing is useful in identifying the partial discharge inception voltage (the voltage level at which partial discharges are initially detected). Once partial discharges occur, the voltage can be reduced to determine the partial discharge extinction voltage (voltage level at which partial discharges cease). These measurements, along with the partial discharge level at the line to neutral voltage of the coil, are helpful in determining the overall quality of the consolidated and fully cured coil.

Electrolock can also perform high-voltage tests on specific materials or an insulation specimen, instead of a fully manufactured coil. These examinations cover a number of aspects important when considering that material or specimen as a part of a coil’s insulation system:

• DC Voltage Breakdown
• Insulation Resistance
• Surface Resistance
• Volume Resistance
• Capacitance

Tailored Solutions for Stator Coils and More: Electrolock offers an extensive list of solutions for applications relating to VPI stator coils and bars and resin-rich stator coils.

Learn More from our Experts in High Voltage Insulation Testing

Electrolock has been engineering solutions for the high-voltage electrical, battery, and thermal insulation industries since 1957. Our focus has always been and will continue to be focused on creating unique and tailored solutions to service the most demanding requests. From insulating motor and generator coils to wire and cable tapes, we have distributor relationships and engineering experience to find the right application solution for you.

With Electrolock’s dedicated three-step process, we’ll analyze and validate the insulation systems — and potential changes to them — used in your high voltage coil manufacturing.

Connect with Electrolock today to schedule a one-on-one evaluation regarding your high voltage insulation testing needs and application specifics.

When utilized properly, our Polyshrink and Freebond shrink products deliver assistance to production teams working with high voltage coils and electrical composites in reaching several goals through implementing one solution:

• Removal of voids in the resin, or between layers
• Elimination of foreign object debris (FOD)
• Improved lamination of the composite material
• Superior surface finish
• Better mechanical strength from the cured part

These polyester heat shrink tapes and films can be custom designed to enhance specific application uses, but all deliver on their primary purpose — optimize compaction force during the curing cycle. When working with composites, or high voltage components like resin-rich coils, a resin must be applied between the material layers to create the necessary bond. Polyester heat shrink film or tape is wrapped around the composite or high-voltage coil; Compression occurs during the curing when that tape shrinks and compacts under heat.

As the tape shrinks, the pressure that is exerted in the process forces resin through the composite matrix and between the layers of the material. This brings the layers together as much as possible and reduces voids in the finished part.

This primary function can be further augmented with customization options. Electrolock, for instance, offers multiple product lines to target specific uses, offer greater shrink percentages and compaction strength, perforated or non-perforated tapes depending on the need for outgassing, or release coatings on one or both sides of the polyester heat shrink material.

To get the best results from any heat shrink taping or filming process, it’s critical to consult with an experienced engineering team. Expertise is needed to select the correct type of tape, the thickness needed, and what shrink percentage will deliver the proper amount of compaction force during curing. Film or tape that shrinks too much, or not enough, for example, will have a negative impact on the final product, leading to material waste and extra cost.

We Provide Solutions: Electrolock is your source for Isovolta mica tape productions, widely used in medium and high voltage coil construction and insulation.

3 Examples of Polyester Heat Shrink Tapes and Films

Electrolock’s line of PolyShrink Tape and Freebond Release Film products offers the flexibility and adaptability to conquer any compaction processing challenge involving high-voltage coils or composites. Our PolyShrink tape comes with our proprietary ‘non-silicone’ release coating on one or both sides to ensure an easy release from the cured part. Freebond film is uniquely made to bond to itself during a cure cycle while still being capable of acting as a release film on the part.

Here’s a closer look at more options for both PolyShrink and Freebond, including some technical specifications.

PolyShrink Tape — Our baseline polyester heat shrink product, PolyShrink Tape comes in variable shrink percentages (210, 212, 218, and 220 corresponding to 10, 12, 18, and 20 percent) with usage temperatures between 200-400°F. When compacting force is your primary concern, this tape delivers with a wide range of shrink percentages able to closely match what is needed. It is slit to your desired width and wound on 1.5 or 3-inch interior diameter cores with a minimal amount of thickness (0.002 inches or 2 mils).

Freebond Release Film — A tough, flexible composite film with multifunctional properties, this product has nominal shrink percentages (2 to 4 percent) with a finished thickness of 2 mils (0.002 inches) and practical use up to 300° F. Freebond provides excellent release characteristics from most cured epoxy resin systems and retains higher tear and tensile properties than conventional release films. A three-ply material with a poly core, Freebond will bond to itself that aids in removal after the finished part has cooled. It is NOT coated with silicone or fluoropolymer, thus avoiding the risks associated with products using such coatings.

PolyShrink RR Tape — This is another durable, flexible, shrinkable polyester tape with PTFE coating on both sides to provide enhanced characteristics. Optimum shrink is achieved at temperatures between 80-180°C, making it suitable for applying sufficient compression during heating or curing. PolyShrink RR is generally removed after application. The tape is wound on 1.5 or 3-inch cores and is provided slit to your desired width.

Tailored Solutions for Stator Coils and More: Electrolock offers an extensive list of solutions for applications relating to VPI stator coils and bars and resin-rich stator coils.

Turn to Electrolock for Polyester Heat Shrink Tape and More

Electrolock has been engineering solutions for the high-voltage electrical, battery, and thermal insulation industries since 1957. Our focus has always and will continue to be focused on creating unique and tailored solutions to service the most demanding requests. From insulating motor and generator coils to wire and cable tapes, we have distributor relationships and engineering experience to find the right application solution for you.

From top-end, specialized lab equipment to the expertise-laden technicians and engineers conducting testing of insulation materials, Electrolock has the facilities and personnel required to find answers, validate selections, and create bespoke solutions.

Contact Electrolock today to schedule a one-on-one evaluation regarding your polyester heat shrink material needs and application specifics.

When reliability is critical, knowledge and validation hold even more power. Every manufacturing system consists of different methods, materials, operators, and equipment. How these system components work together can make a huge difference in the quality of coils, motors, and generators a company produces. Learning which electrical insulation materials work best in your process will reduce instances of failure and extend the life of your finished products.

But accessing this kind of information, including qualifying tests on proposed materials and the analysis of failures, requires a testing partner with highly specialized equipment and experienced engineers to conduct extensive analytical medium and high voltage testing. If a coil experiences a failure, do you have an analytical lab you can go to for dissection to find the specific reason? Are your resins failing to cure properly? The right testing partner can tell you why. Are you conducting the necessary tests on your ground wall to see if the resin is penetrating properly?

For more than 60 years, Electrolock Inc. has been engineering solutions for the medium and high voltage electrical, battery, and thermal insulation industries. With decades of experience and using leading-edge technology, Electolock can identify, examine, evaluate, and compare your insulation materials. Performing tests on the chemical, electrical, mechanical, and thermal properties of these materials finds the right fit for your specific application.

Whether you’re using vacuum pressure impregnation (VPI), resin-rich technology, or a vacuum and pressure autoclave system, testing insulation materials enables the design and construction of the best insulation system for your application.

Explore Our Battery Solutions: Electrolock covers every aspect of battery insulation, from dielectric barriers to thermal runaway protection. See more here.

Essential Analytical Testing for Insulation Materials

Given the investment level and critical nature of medium and high voltage coils, it’s of absolute importance that manufacturers gain insight into every facet of the production. Given the cost of failure — in time lost for repair or to replace, and the expense — it makes sense to address every aspect of the insulation system with thorough and expert testing of the insulation materials to be used.

Seeking analytic laboratory testing is important to validate the processes and materials in place. There is too much invested in the overall machinery to not do everything possible to ensure its success. Failure for such devices can result from the smallest component breaking down, the improper adhesive being used, or the resin not curing properly.

When searching for the right partner to execute the precise testing of insulation materials, it’s important to consider their complete portfolio. Do they have extensive experience in the field? Do they have access to the needed equipment to execute the tests required? Can they perform the tests necessary to identify, evaluate and compare your insulation materials?

Here’s a quick look at some of the many tests and top-level equipment utilized by Electrolock to analyze every aspect of the insulation system used by medium and high voltage coils.

Differential Scanning Calorimeter (DSC)

A DSC, and the tests conducted with it, are fundamental tools in thermal analysis. These measure the exothermic and endothermic energy properties of a sample during a temperature ramp-up. In other words, using a DSC allows analysis of the temperature and heat flow associated with material transitions as a function of time and temperature.

This is critical for testing resins and epoxies, specifically their curing characteristics. It allows engineers to characterize the degree of cure in a thermoset, and to determine the kinetics of the cure.

Dynamic Mechanical Analyzer (DMA)

While a DSC measures how a material handles heat flow under a temperature ramp up, a DMA test will gauge the mechanical strength of a sample under similar conditions. Both DSC and DMA will be used to determine different characteristics of a material — such as a resin or epoxy — and if it is suitable for use in the application.

DMA is a testing technique (and analytical instrument) that measures the physical properties of both solids and polymer melts, reports on modulus and damping, and is programmable to measure the force, stress, or strain the material can handle. A resin may be suitable for use based on DSC results, but could show a lack of durability under DMA procedures; this could either mark the material as the cause of a failure or exclude it from being used as part of a new insulation system.

Thermogravimetric Analysis (TGA)

Similar to DSC and DMA testing, TGA also examines a material sample before and after a temperature ramp-up process. It’s used to determine a material’s thermal stability and its fraction of volatile components by measuring the weight change that occurs as the sample is heated at a constant rate.

TGA is helpful in learning how long a given material could be expected to last in a given application. For example, let’s say a sample saw a 10% percent weight loss in a test under 300ºC. Using that data, you could extrapolate how long the material would last before it lost too much of its weight to remain effective against the specifics of the proposed application.

TGA, like DSC or DMA, is another tool that can detect the properties of elements involved in medium and high voltage coils — like resins, epoxies, and other insulating materials — and examine whether they’re a good fit or a cause of failure.

Fourier Transform Infrared Spectroscopy (FTIR)

This instrument and technique are used to identify functional groups and chemical bonds in a sample by producing an infrared absorption spectrum. The resulting profile of the sample is a molecular fingerprint that can be used to screen and scan other samples for many different components.

Using FTIR, lab technicians can determine what kind of monomer or solvent is present in a given resin. They can identify which epoxies might be present in a sample. If you have an unknown substance, FTIR testing can be performed to find out what it is, or even ‘reverse’ engineer a proven material without knowing its specific origin or makeup.

Tan Delta (ITTD) Testing

ITTD testing measures the dissipation factor — sometimes referred to as tan delta or tangent of the loss angle — and in general terms measures the quality of the insulation system in place.

As the resin in the insulation cures, the electrical insulation properties improve. One would want to be sure that when the cure cycle is completed the dissipation factor as a measure of the insulation integrity is in an acceptable range.

Other Equipment

Beyond the techniques and devices already mentioned, a highly qualified and equipped analytical lab testing insulation materials has access to a host of other equipment. Here’s a snapshot of the other equipment found in the Electrolock analytical testing lab.

• Gurley Densometer — Measures porosity or air resistance of sheet-like materials
• Contact Angle Meter — Allows direct measurements of surface tension and interfacial tension
• Electron Microscope — Essential tool for quality control and failure analysis
• MTS Tensile — Provides tensile testing with strain measurement techniques
• pH Meter — Measures the hydrogen ion concentration in a liquid solution
• Gurley Bending Resistance Tester — Measures the force required to bend a wide variety of materials under controlled and repeatable conditions
• Muffle Furnace — A type of laboratory furnace that isolates samples and is ideal for materials testing and quality control

Tailored Solutions for Stator Coils and More: Electrolock offers an extensive list of solutions for applications relating to VPI stator coils and bars and resin-rich stator coils.

Trust Electrolock for all Your Analytical Testing

Electrolock has been engineering solutions for the high-voltage electrical, battery, and thermal insulation industries since 1957. Our focus has always and will continue to be focused on creating unique and tailored solutions to service the most demanding requests. From insulating motor and generator coils to wire and cable tapes, we have the distributor relationships and engineering experience to find the right application solution for you.

From top-end, specialized lab equipment to the expertise-laden technicians and engineers conducting testing of insulation materials, Electrolock has the facilities and personnel required to find answers, validate selections, and create bespoke solutions.

Contact Electrolock today to schedule a one-on-one evaluation regarding your analytical testing needs and application specifics.

Electrolock strives for excellence in every design and solution we offer and works directly with customers to ensure all our products meet their specific application requirements. With more than 60 years of serving high-voltage motor and generator manufacturers, and wire and cable manufacturers, Electrolock is proud to play a part in making the electricity millions use every day a consistent and reliable resource.

Isovolta mica tapes play a huge role in this mission and serve as a vital part of many insulation solutions. Rotating electrical machines must permanently withstand maximum stress. A perfectly coordinated insulation system forms the foundation for meeting these high standards and achieving the desired performance of generators, motors, and drives. With decades of experience in processing mica and various resins, Isovolta offers the highest quality mica tapes for generators of all types and sizes.

Electrolock applies its approach of finding bespoke solutions to specific applications that our customers face. Working from a pair of North American locations, Electrolock will consider every facet of your individual application and then tap into our array of engineering expertise and distributor partnerships to find the ideal answer. Today, we’ll examine the types of mica used for coil insulation and take a quick look at Isovolta mica tape examples of each.

Looking for compacting tape instead? Electrolock also has shrink and release tapes to facilitate the processing of high-voltage coils and composites. Learn more here.

Types of Mica Used in Medium and High Voltage Coils

Because of its higher electrical purity, nearly all medium and high voltage coils use muscovite mica. Muscovite mica is processed in two ways: a calcined process and an uncalcined process. Both methods produce high voltage mica tapes that exhibit high breakdown voltages, good voltage endurance, and low dissipation factors. While both tapes have sufficient electrical properties, in general, calcined muscovite exhibits slightly higher breakdown, and uncalcined muscovite mica typically has greater voltage endurance.

Calcined Muscovite

In the calcined process, chunks of flake muscovite mica are passed through a high-temperature rotary kiln (sometimes called a rotary calciner) and the tumbling heat breaks some intermolecular bonds. This exfoliates the flake and allows for various mixing equipment to produce very small mica flakes. These tiny, calcined muscovite flakes have a small diameter-to-thickness ratio. When made into a paper and then high voltage ground wall insulation, the calcined mica paper tapes exhibit a high voltage breakdown.

Uncalcined Muscovite

Under the uncalcined process, the chunks of flake mica undergo an ablative process using high-pressure water jets that break up the rock into small mica flakes with a large diameter-to-thickness aspect ratio. These flakes are then segregated by size to assure a consistent mica paper with the proper flake diameter-to-thickness aspect ratio. Mica tapes made with uncalcined mica paper exhibit longer voltage endurance because of the longer tracking path around the larger aspect ratio flakes. There is also more mica per given thickness when compared to calcined papers.

Explore Our Battery Solutions: Electrolock covers every aspect of battery insulation, from dielectric barriers to thermal runaway protection. See more here.

Popular Uses for Different Isovolta Mica Tapes

It should be stressed that you can make acceptable high voltage insulators with either kind of mica tape, but each has its own particular strengths and preferred intended uses. Calcined mica is generally preferred in medium voltage vacuum pressure impregnation coils and is often made with higher binder contents. In medium-voltage coils impregnation is easier because of the lower insulation builds. The calcined mica tapes with higher binder content are more durable, and easier to tape, and voltage stress is typically much lower making voltage endurance requirements easier to satisfy. Calcined muscovite mica is also preferred in most resin-rich tapes for both medium and high voltage coils because the smaller aspect flakes are less susceptible to blocking in self-wound resin-rich tapes.

• Isovolta Mica Tape example — Calmicaglas® 409 consists of mica paper based on calcined muscovite, a glass cloth carrier, and thermosetting epoxy-novolac. This mica tape is used for insulation of coils and bars of motors and generators up to the highest output and nominal voltage and also can be used for manufacturing molded parts like commutator caps, tubes, and cylinders.

Uncalcined mica tapes are predominantly used in the high voltage vacuum pressure impregnation process. Uncalcined mica tapes are typically made with low binder levels, with contents around 8 percent by weight. These low binder tapes are more fragile and typically applied with robots where the taping tension and taping angles are more controlled and consistent. The advantage of the low-binder, high aspect ratio mica flake tapes is easier impregnation through thicker ground walls and higher voltage endurance when voltage stress is greater. There are new resin-rich tapes on the market taking advantage of the increased mica-to-thickness ratio, however, as blocking can be an issue so it is important to take special care during manufacturing and taping.

• Isovolta Mica Tape example — Poroband® 410 consists of highly porous mica paper based on uncalcined muscovite, reinforced on one side with glass cloth, and a small amount of Bisphenol-A epoxy-resin. Poroband® 410 does not contain any accelerator or hardener and is used for impregnation with accelerated resins. The low bonding content and the uncalcined mica paper are responsible for the high porosity of the tape, which enables a quick penetration of resin through a considerable number of layers. This tape is used for continuous insulation of coils and bars of low and high voltage machines as well as interlayer insulation in dry type transformers if the vacuum pressure impregnation process is used.

Both types of mica tape have been used successfully for decades in many different applications and designs. Understanding the slight benefits of each can help distinguish which might be best for your specific application. The two examples of Isovolta mica tapes above represent only a small sampling of the many kinds of mica-based tapes the manufacturer offers.

Tailored Solutions for Stator Coils and More: Electrolock offers an extensive list of solutions for applications relating to VPI stator coils and bars, and resin-rich stator coils.

Make Electrolock Your Mica Tape Partner

Electrolock has been engineering solutions for the high-voltage electrical, battery, and thermal insulation industries since 1957. Our focus has always and will continue to be focused on creating unique and tailored solutions to service the most demanding requests. From insulating motor and generator coils to wire and cable tapes, we have distributor relationships and engineering experience to find the right application solution for you.

Contact Electrolock today to schedule a one-on-one evaluation regarding your need for Isovolta mica tapes and application specifics.

Electrolock applies its approach of finding bespoke solutions to specific applications faced by our customers. In this way, designing, manufacturing, and implementing laminates — and in particular high-temperature laminates — is an essential part of what Electrock does from its two North American locations.

For instance, using laminating you can add foil-faced materials to use on a high-temperature gasket. You could include a laminate with an absorbent outer layer for use on a component that needed to remain dry or avoid moisture. You can laminate a part or cutout to apply an additional adhesive to give the finished product a peel & stick capability. With the right production combination, you can combine several needs into one laminate; For example, you could add a static dissipating layer to a laminate already consisting of a dielectric layer and a thermal isolation layer — then have the entire composite backed by an adhesive.

Electrolock will consult with you to find the right combination to serve the demands of your specific application, and has extensive experience in working with high-temperature laminates. Electrolock has the ability to work with high-temperature films, thermoplastics, fabric substrates, and high-temperature adhesives for laminates that are effective up to 525°F. Other laminate options to note include:

• Electrolock can design laminates with multiple substrates, up to six layers
• Electrolock is experienced with many laminate materials, including polyimides, fiberglass, foils with glass backing, and brand options like Kevlar®
• Electrolock has expertise with a wide range of adhesives, including various acrylics, phenols, polys (polyurethane/polyesters), epoxies, and fluoroelastomers

With these capabilities, Electrolock can devise and manufacture the laminate your application demands. Below are just three of the many possible examples of Electrolock providing high-temperature laminate solutions.

Looking for tape instead? Electrolock also has shrink and release tapes to facilitate the processing of high-voltage coils and composites. Learn more here.

3 Examples of High-Temperature Laminates

CraneGlas®

CraneGlas is a nonwoven fiberglass paper made from fine diameter electrical grade fibers of uniform length, with a PVA binder. The paper is capable of operating at high temperatures, is flame retardant, and is available in a range of thicknesses. It can be supplied slit to your required width with a wide variety of put-ups.

CraneGlas can be implemented in many different applications, including chemical trace lines, thermal gaskets, battery separators, and photovoltaic panels. It can also be used, as a layer in copper-clad laminate, for printed wiring boards.

Go-Therm Thermal Runaway Barrier

Go-Therm is a highly flexible, silicone-based barrier designed for use as an interior lining in a battery case. It provides superior performance to protect the pack from the ejecta and flames caused by an incident of thermal runaway. More flexible than rigid mica plate, Go-Therm can also be used as a thermal runaway barrier between prismatic cells in a single module. Parts can be fabricated to size and are available with a pressure-sensitive adhesive on one side.

Go-Therm comes in two types. Go-Therm 150 is a glass one-side silicone laminate. Go-Therm 315 is a fiberglass-backed (both sides) 1.5mm thick laminate.

Keveloc®

Keveloc is a puncture-resistant laminate designed to provide cut-through or puncture resistance to areas under compression pressure or shear forces. Keveloc is a barrier insert that withstands operating temperatures for Class F or Class H machines — winding insulation max temperatures of 155°C and 180°C respectively — and is typically employed as a crossover barrier for roebel conductors in high voltage coils.

Available in a thickness of just .015”, Keveloc still has a robust tensile strength (175 pounds/inch width) and shear puncture resistance (1,381 lbs.).

Explore Our Battery Solutions: Electrolock covers every aspect of battery insulation, from dielectric barriers to thermal runaway protection. See more here.

Trust Electrolock with Your High-Temperature Laminates

Electrolock has been engineering solutions for the high-voltage electrical, battery, and thermal insulation industries since 1957. Our focus has always and will continue to be focused on creating unique and tailored solutions to service the most demanding requests.

Electrolock has extensive experience working with multiple materials to design the right laminate for your application, produce that laminate, then add finishes to aid in application use. Our complete line of manufacturing services can slit the material to the necessary width, produce punched parts, add pressure-sensitive adhesive, enable die-cutting, and much more.

Electrolock has the capability to produce roll-to-roll lamination for a large swath of industries, including battery insulation, automotive, motor generator coils, and many aspects of the electronics sector. With roll-to-roll lamination, you’ll receive continuous, consistent delivery of the material leading to a more efficient and cost-effective process.

Contact Electrolock today to schedule a one-on-one evaluation regarding your need for high-temperature laminates and application specifics.

Cutting tables, whether outfitted with traditional plasma cutting tools, lasers, or other implements, are some of the most finely-tuned, efficient, and versatile tools for producing finished parts or even additional tooling out of a vast assortment of materials. The computer-automated nature of CAD cutting tables allows for a precise cut and an extremely high level of accuracy for every repetition or process.

CAD (Computer Aided Design) refers to the use of computers in helping the creation, modification, analysis, or optimization of a design. Software is used to increase the productivity of the process, improve the quality of the design, and even create a database for further manufacturing. CAD files, containing either a 2D or 3D design, contain the blueprint, schematic, or technical drawing of an object. A CAD cutting table uses these files to produce the object in a precise and perfectly repeatable manner.

With the basics covered, it’s time to look at how using a CAD cutting table can benefit fabrication and manufacturing.

Thermal Performance: CAD table cutting is a common way to design special thermal insulation solutions. Examine Electrolock’s full set of offerings here.

Why Using a CAD Cutting Table is Essential

Because of their ease of use, setup, and rapid deployment time, the use of a cutting table is often prized in the prototyping stage. Once final drawings or schematics are set, it’s a relatively quick process to set up a CAD table for quickly cutting the desired part out of the chosen material to further the development process of the theorized solution to an engineering problem.

Another key use of the device is to manufacture tooling (once designed) that can then be used in other fabrication applications. For example, a CAD cutting table might be used in the creation of a die to be used later in a rotary die-cutting process.

Given the size and dimensions of a typical CAD cutting table, the device is best used for cutting out large, two-dimensional shapes or parts. Good examples would be larger, mostly flat, parts used in automotive or industrial applications (like gaskets), or shielding components in high-temperature thermal applications.

A CAD cutting table is best implemented when you need large parts quickly, and lots of them. If you already have the CAD file, you can go right to the production floor and get started nearly immediately. With the use of a CAD table, you can cut the time needed to transition from prototyping to full production. The use of CAD files leads to automation of the process, and the ability to go roll to roll with the materials needed without delays and with the consistency ensured by the computer-assisted design.

Flexible materials, those not especially dense or rigid, work best with CAD cutting tables for fabrication. This still leaves a wide range of possibilities, including (but not limited to):

• Laminates
• Glass
• Kevlar®
• Woven or non-woven fabrics
• Coated fabrics
• Film
• Fiberglass

While the strengths of a CAD cutting table are evident, there are still circumstances when other fabrication techniques may be preferred. For example, die-cutting is better equipped to handle the fabrication of complex parts or those that contain a lot of different cuts per inch. You’ll want to explore rotary die-cutting for medium to small parts in high volumes, for parts with more intricate shapes, or when you seek kiss-cut capability — commonly used for some material choices like foils, Nomex®, and Kevlar®.

CAD table cutting and die-cutting are just two of the fabrication processes available through Electrolock. Whatever form you need your materials converted to Electrolock can help with slitting and rewinding, coating and saturation, sheeting and shearing, spiral wound tubing, kitting and packaging, and much more.

Go Deeper with Rotary Die-Cutting: Learn more about why rotary die-cutting is commonly used in the fabrication of insulation solutions.

Electrolock has a Complete Line of Complementary Services

Electrolock has been engineering solutions for the high-voltage electrical, battery, and thermal insulation industries since 1957. Our focus has always and will continue to be, focused on creating bespoke — unique and tailored — solutions to service the most demanding requests.

Electrolock innovates and produces bespoke solutions for every client to fit the exact requirements of your specific applications. By collaborating with your business, Electrolock will design, fabricate, and then fully test potential solutions. By validating — through an extensive in-house testing system — before entering production, Electrolock is able to save both time and expense on the back-end of a project.

By choosing Electrolock, you won’t simply be picking a product from a catalog or menu of options. You’ll work with Electrolock’s experienced, expert-level team to create a custom-designed answer to your particular problem — complete with fabrication options.

Contact Electrolock today to schedule a one-on-one evaluation of your material needs and application specifics.

Spiral wound tubing is produced by wrapping several strips, or laminations, of adhesive coated materials such as plastic films, papers, or other substrates, alone or in combinations, at an angle, over a mandrel that forms the tube. The adhesives used are designed to be compatible with the materials used to make the tube and, when necessary, with chemicals and resins found in the end-use application.

This combination of materials leads to unique tube characteristics that are formulated with insulating properties in mind for many applications. Spiral wound tubing can provide mechanical (abrasion and cut-through), chemical (resistance to oils, greases, etc.), heat, and electrical (dielectric strength) resistance.

But this versatility, through the use of different materials to craft different resistances, is just the beginning. Further design enhancement can be added for many more high-performance applications such as sleeving for capacitors and batteries, thermal cutouts, slot liners, EMI shielding, and more.

Spiral wound tubes are not a one-size-fits-all product and are designed to service customer-specific requirements.

Examining Spiral Wound Tubing Features

The importance of finding improved ways to incorporate spiral wound tubing into your manufacturing process should not be overlooked. It is important to your application’s success to have parts that are designed using the best materials that work efficiently to meet your performance and process requirements. The right supplier can add value with creative design and manufacturing.

In addition, Electrolock can supply cut to length parts, long lengths, flared ends, sealed end caps, notched cuts, angled cuts, punched holes, and continuous length tubing among other options. These special configurations, used in combination with specifically designed spiral tubing materials, can enhance the end product. Here’s a quick look at many of the general spiral wound tubing features available.

Notched

Cut outs or notches can be fabricated in the tubes. These options include slotting, notching, flared ends, and more as dictated by your specific application.

Formed

Using thermoforming, we can fabricate tubes that feature a shoulder or end cap as needed.

Cut to Length

Precise cut-to-length fabrication is possible. This allows exact matching and leaves no wasted material if you require a solution that falls outside standard lengths.

Thin or Thick

Our fabrication abilities mean we can provide spiral wound tubing with very thin walls — less than 0.003” are possible. Or we can provide thick wall constructions, of up to 0.120” depending on the materials selected.

Colored

If you need visual touches for aesthetic or organization requirements, our spiral tubing features the ability to be flood coated with different colors.

Sealed

If a thermoformed end cap is not sufficient, our spiral wound tubing can be produced with heat-sealed end caps for improved capabilities.

Sonic Welded

For the ultimate in end caps and sealing, ultrasonically heat-sealed tubes can be made with high reliability.

Designing Spiral Wound Tubing

At Electrolock, understanding that each company’s needs are unique and deserve a unique engineering approach is one of our core principles.

With an extensive background in materials and design, Electrolock uses its experience to find the custom spiral wound tubing solution to fit your application and budget.

At Electrolock, we can supply spiral wound tubing using a variety of materials, with different performance characteristics that perform well in varying applications. This range of materials includes:

• Aramid/Nomex®
• Polyimide/Kapton®
• PET
• PEEK
• Ultem®
• Fiberglass
• Felts
• Foils
• Porex *UV reflective Tubing*

In addition to the fabrication options listed above and our ability to provide material options for spiral wound tubing, it’s important to also account for other tubing characteristics needed. Spiral wound tubing can be produced as heat shrink or non-shrink, conductive or semi-conductive, or made with high cut-through resistance products like Kevlar or glass. Electrolock also designs and produces UV reflective tubing used to sanitize inline air handling and fluid transport systems.

Explore Spiral Wound Tubing Features with Electrolock

Electrolock has produced spiral wound tubing, for high voltage, thermal, and battery applications for more than 60 years. Electrolock, Inc. uses its extensive expertise in design, material selection, and analytical testing to find the ideal solution for your specific application.

Electrolock, with its full in-house testing capabilities, validates all the performance requirements once a solution is found. As your partner, our team will be present at your facility during trials to ensure the performance of your application. When searching for a spiral wound tube, every application is different. So why compromise on performance by limiting your options to off-the-shelf products instead of working with a partner that provides the spiral tubing features you need?

Contact Electrolock today to schedule a one-on-one evaluation of your material needs and application specifics.

The long-term forecasts for new EV sales in the US through 2030 cite an expected strong growth curve. For example, approximately 29.5% of all new car sales in 2030 are expected to be EVs compared to the roughly 3.4% seen in 2021. This means a jump from about 500,000 new EV sales in 2021 to around 4.7 million in less than a decade.

The power for EVs comes from batteries, which are typically a combination of three distinct units nestled inside one another — individual cells, groups of cells contained within a module, and the battery pack. The cells are the core of the battery as they concentrate the substances that are used to produce electrical energy. They are high-performing, rechargeable accumulators, and often are Lithium-ion, Lithium-ion polymer, or Lithium-metal polymer in type.

An EV needs a thousand times more power to operate than your everyday smartphone. So while both an EV and a phone may use a similar type of battery, many more are needed in the battery design for an EV. These cells are grouped into different modules to better protect them and make their replacement easier in the event of a breakdown.

The battery pack gathers the modules together with a cooling system and is managed by a Battery Management System (BMS), which controls the state of the battery as a whole — the unit’s temperature, voltage, and intensity among other factors.

Outside the cell insulation, like battery insulation sleeving, is critical for the continued safe and ideal operation of batteries used in these and similar applications. Battery sleeving helps ensure each cell contained in a module is protected from other cells in that enclosed environment.

4 Battery Insulation Sleeving Options

When exploring battery insulation sleeving or pouches, dielectric protection or protection against thermal runaway is a primary focus. Guarding against thermal runaway is of particular interest in the EV industry, and Electrolock has written before about specific solutions in that area. But here we’ll be examining outside the cell dielectric protection provided by sleeves, pouches, and bottom and side edge seals. Below are four heat shrink tubing sources that offer the dielectric protection needed for use in battery insulation.

PET Layflat Tubing 740 HS

This lineal seal tubing comes as heat shrink sleeves with an extremely thin wall that provides both dielectric protection and physical toughness. The 740 HS is composed of a one-side, anti-static treated modified polyester (PET) film that is clear in color but can be printed on or colored. Formed into tubing, 740 heat shrink sleeves shrink quickly — roughly in 10 seconds at 100ºC — and uniformly around cylindrical shapes.

740 linear sleeves are available in an array of diameters and lengths and can be designed to suit machine and process requirements.

PET Layflat Tubing 800 FRC

Another lineal seal tubing solution, 800 FRC heat shrink sleeves also have an extremely thin wall and provide sleeving that offers dielectric protection and physical toughness. This tubing features a one-side, anti-static treated modified PVC film. Like the 740 HS, the 800 FRC is clear but can be printed or colored and shrinks quickly — again in 10 seconds at 100ºC — and uniformly around multiple shapes.

800 FRC linear sleeves come in a variety of diameters, lengths, and widths, and can likewise be designed to fit machine and process requirements.

Heat Shrink Spiral Wound Tubes

Heat shrink polyester sleeving is used as a protective cover against abrasive or chemically harsh environments while also offering high dielectric protection, good tensile strength, and excellent chemical resistance. This sleeving will shrink in length and diameter when subjected to oven temperatures above 300ºF or by use of a heat gun or similar heating device.

Heat shrink polyester sleeving can be produced to your required diameter, wall thickness, and length. The normal diameter range is 0.096” to 3.00” with wall thickness ranging from 0.002” to 0.006”. Custom colors or striping are available on request.

Continuous Heat Shrink Spiral Wound Tubes

This product includes all the essential elements of heat shrink polyester sleeving, including dielectric protection, chemical resistance, and tensile strength with the added benefit of ease of application in automated processes. Like its counterpart, it too will shrink in length and diameter when heated to temperatures above 300ºF.

This is our standard spiral wound tubing supplied on continuous rolls, up to 2,000 feet long, that can be used for automated assembly processes.

Achieve Essential Battery Insulation Sleeving with Electrolock

Working with an experienced, trusted partner for battery insulation sleeving maximizes the chances for success in a specific application and minimizes the risk for delays, material loss, and downtime once implemented. Electrolock, Inc. has extensive expertise in analytical testing and designing solutions to find the ideal solution for your specific application.

Further engineering assistance is provided after the battery insulation sleeving is designed. Electrolock has full in-house testing capabilities to validate all the performance requirements. As your partner, our team will be present at your facility during trials to ensure the performance of the material with your application.

Electrolock has produced premier custom insulation products, including the use of many spiral wound tubing materials, for the high voltage electrical, thermal insulation, and battery industries for more than 60 years. We have deep experience in working with any material to solve insulation challenges.

Electrolock’s focus has always been on creating bespoke — unique, tailored to each client — answers to service the most technically demanding requests. So you won’t simply pick a product from a catalog; you’ll work with Electrolock’s team to create a custom-designed answer to your particular problem.

Contact Electrolock today to schedule a one-on-one consultation or evaluation on your material needs or application specifics.

First, What is Mica??

Mica is the name given to a group of minerals that naturally forms in layers with a two-dimensional structure. Because of this two-dimensional structure, mica can be split, or cleaved, into very thin sheets. Specifically, mica has near-perfect “basal cleavage”, meaning it can be easily split into one plane. This allows mica to be processed into very thin films while retaining high dielectric and thermally resistant properties.

In the electrical industry, mica usage is dominated by two types — muscovite and phlogopite. Phlogopite is amber or dark green in color, has excellent heat resistance, and outperforms during voltage endurance testing over time. Muscovite also has exceptional heat resistance and can endure higher voltages during voltage breakdown testing. We’ve detailed both calcined and uncalcined muscovite before and how each could be the better choice depending on the desired application.

Why Use Mica Tape for Cables?

The properties of mica make it an excellent choice for wire and cable insulation in applications with exposure to high temperatures and direct flame. Fire safety applications require emergency power and communication circuits to remain operational during a fire. It is critical that fire alarms in buildings and exhaust fans in tunnels continue to operate well after being exposed to direct flames and temperatures up to 1800 F. Additional benefits of mica insulation in wire and cable applications include its characteristics of being flexible, lightweight, chemically inert, hydrophobic, and durable.

How is Mica Applied to Wire and Cable?

First mica is broken down to create mica paper — a paper-like material made of miniature mica flakes held together by natural cohesive force between adjacent flakes. Mica paper is very fragile and requires further processing to add strength and durability. Mica paper is combined with various reinforcing substrates and bonding resin to create mica tape. The thermal, electrical, and mechanical requirements of the application weigh heavily on the bonding agent and substrates selected.

Mica tapes are applied to wire and cable at high speed continuously by means of a linear or spiral wrapping machine.

Multiple Custom Mica Tape Solutions from Electrolock

Since 1957, Electrolock has provided premier insulation products for the high voltage electrical, battery, and thermal insulation industries. This experience and expertise are evident in the development of Electrolock’s proprietary Pyrodox® mica cable tapes.

As one of the many high voltage electrical insulation solutions Electrolock provides, Pyrodox is used in essential and demanding applications including fire survival for control and power cables, oil well, thermocouple, aircraft, mass transit, and shipboard cables. Pyrodox mica tape for cables offers the high-temperature resistance and thermal insulation that comes with the use of thin mica paper bonded with halogen-free silicone resins to the appropriate substrate for your application.

With Electrolock, you’ll gain access to engineering consultation and customization options to maximize the success of your application. Pyrodox cable tapes are available in thicknesses of less than .003” for taping ultra-fine wire gauges. These tapes can be precision-slit to widths of less than 1/8th of an inch and supplied on custom spools (traverse, step, taper, etc.) containing thousands of yards of continuous tape. Long continuous tape lengths reduce taping machine downtime resulting from pack changeovers.

You also won’t be locked into one configuration. Pyrodox can be customized using any combination of the following materials. Each combination is engineered to meet your application’s unique requirements.

• Pyrodox® Mica Types
  • Phlogopite
  • Calcined phlogopite
  • Muscovite
  • Calcined muscovite
  • Synthetic
• Pyrodox® Reinforcements
  • Woven fiberglass
  • Inorganic yarn
  • Polyethylene film
  • Polyester film
• Pyrodox® Binder
  • Non-alkaline, halogen-free, high-temperature silicone binder
• Pyrodox® Coating
  • Inorganic coating can be applied to either side of any configuration to decrease flaking, stringing, and sticking issues during high-speed wrapping.

Wrap Up Insulation with Mica Tape for Cables

Electrolock’s focus has always been on creating bespoke products, tailored to each client’s specific needs. You won’t simply pick a product from a catalog; you’ll work with Electrolock’s team to develop a custom-designed solution.

Contact Electrolock today to discuss your application!

Before we get into the many options available from an expert-level provider of insulation products, let’s examine the important functions of shrink and release tape.

Dual Purposes for Specific Requests

The primary purpose for any industrial shrink tape, including those dealing with high-voltage coils and electrical composites, is to optimize compaction forces during the curing cycle. When working with composites, a resin must be applied between the material layers to create the necessary bond and compress them. The tape, or film, is wrapped around a composite element or high-voltage coil and placed in an oven where it begins to shrink.

As the tape shrinks, the pressure that is exerted in the process forces resin through the composite matrix and between the layers of the material. This brings the layers together as much as possible and reduces voids in the finished part.

Shrink and release tape performs this task, but differentiates itself in its ability to also provide clean ‘release’ characteristics. After the curing process, shrink and release tape can then be cleanly stripped away — which helps provide a smooth finish to the part and aids in cutting down the bulk and/or size of the finished product.

These additional benefits come with none of the drawbacks of limited customization. Providers of insulation solutions, like Electrolock, will offer multiple product lines to further target specific uses or circumstances. Shrink and release tape can come with a release coating on one or both sides of the product, and can be perforated or non-perforated.

And the shrink tape itself is available in many different core materials that further provide specialization. These materials include (but are not limited to):

• PET (Polyethylene terephthalate)
• FEP (Fluorinated ethylene propylene)
• PI (Polyimide)
• ETFE (Ethylene tetrafluoroethylene)
• OPP (Oriented polypropylene)

With the number of variables involved — the type of film used, the thickness needed, the ideal shrink percentage to apply the right force, and the material selected — it is essential to remember that to get the best results out of this process you’ll need to consult with a qualified engineering team. Expert advice will help you select the correct shrink and release tape, and other specifics, needed for your application.

Want to know more about Electrolock? Read about their engineered solutions here.

5 Shrink and Release Tape Solutions

Electrolock is a premier provider of insulation products for high-voltage electrical, battery, and thermal insulation industries. With more than 60 years of experience, we’ve consistently created bespoke solutions to cover all of our customers’ most demanding requests.

In the area of shrink and release tape, our PolyShrink Tape and Freebond Release Film will give you the flexibility and versatility to tackle any compaction processing issue involving high-voltage coils or composites. Our PolyShrink tape comes with our proprietary ‘non-silicone’ release coating on one or both sides to ensure an easy release from the cured part. Freebond film is uniquely made to bond to itself during a cure cycle while still being capable of acting as a release film on the part.

Here’s a closer look at more options for both PolyShrink and Freebond, including technical specifications.

PolyShrink Tape — Our baseline product offering in this realm, PolyShrink Tape comes in variable shrink percentages (210, 212, 218, and 220 corresponding to 10, 12, 18, and 20 percent) with usage temperatures between 200 and 400 degrees F. This tape will have the best overall compacting force, and comes slit to your desired width and wound on 1.5 or 3-inch interior diameter cores with a minimal amount of thickness (0.002 inches).

PolyShrink R Tape — Available in 210 and 220 varieties (10 and 20 percent shrink), this tape features a PTFE coating on one side to provide enhanced release characteristics. Optimum shrink is achieved at temperatures between 80 and 165 C. The cleaner releasing tape comes in similarly sized thickness (0.05 mm) and is wound on similarly sized cores (38 mm to 76 mm).

PolyShrink T — Coming in two shrink percentages (206T and 210T) and one non-shrink (200T) version for use when preventing deforming during curing is absolutely necessary, this ‘tape’ is often is used as one homogeneous film for excellent release characteristics. Optimum shrink is obtained between 120º and 170ºC, and the film is available slit to desired width the usual thickness (0.002 inches) and core (1.5 or 3 inches) sizes.

PolyShrink HT — With a nylon core and a fluoropolymer release on both sides, this film can easily conform to unusual or complex cross-sections, and has the best releasing tape Electrolock provides. While it doesn’t have the strongest shrink force, it does come in minimum (200HT) and moderate (212HT) varieties. The superior release properties will work in processing temperatures as high as 180 C. Wound on 38 mm or 76 mm cores, this tape comes in 0.05 mm thickness and is provided slit to your desired width.

Freebond Release Film — A tough, flexible composite film with multifunctional properties, this product has nominal shrink percentages (2 to 4 percent) with a finished thickness of 0.002 inches and practical use up to 300 F. Freebond provides excellent release characteristics from most cured epoxy resin systems and retains higher tear and tensile properties than conventional release films. A three-ply material with a poly core, Freebond will bond to itself and provide a solid structure or tube which aids in removal after the finished part has cooled. It is NOT coated with silicone or fluoropolymer, thus avoiding the risks associated with products using such coatings.

Ensure your insulation solutions: Learn more about our experienced, expert-level team here.

Proven Solution Providers

Collaborating with businesses since 1957 to engineer unique and tailored solutions for the thermal insulation, battery, and high-voltage electric industries, Electrolock has amassed the experience and expertise to handle any request.

Electrolock will design, fabricate, and then fully test potential solutions, including identifying the perfect shrink and release tape needed for your application. By validating — through an extensive in-house testing system — before entering production, Electrolock is able to save both time and expense on the back-end of a project. No matter what your material or insulation challenge, Electrolock will help you solve it.

Contact us today to schedule a one-on-one consultation or evaluation on your material needs or application specifics.

With use in applications where chemical or thermal protection, or electrical insulation, is needed, custom spiral wound tubing is applied widely in the electromechanical industry, automotive field, aerospace, and more. Capable of providing robust dielectric strength, spiral wound tubing also helps guard against abrasion damage and tearing.

Construction of spiral wound tubing consists of a spiraling technique. A series of adhesive-coated strips are coupled together and then wound around a mandrel or other tooling to form the tubular shape. The characteristics of the resulting product — be they mechanical, thermal, or electrical — are the sum of the aspects imparted by each of the layers used in the construction. The combination of the layers used is variable and offers a diverse range of potential benefits.

Because of this diversity and array of customizability, spiral wound tubing is designed and proceed according to customer specifications. Collaboration and communication are essential in identifying the purpose of the tubing, how to reach the necessary performance, and which materials and other variables must be included in the solution to attain those goals.

Endless Options for the Ultimate Customizability

Working with an experienced, trusted partner for choosing spiral wound tubing materials will maximize the chances for success in a specific application and minimize the risk for delays, material loss, and downtime once implemented.

Electrolock understands that your company’s needs are unique. That’s why we take an engineering approach to find a bespoke solution for every client to fit the exact requirements of their specific application.

We’ll take the time to ask the right questions, and the answers will lead to the ideal solution. How will this tube be used? What are the performance requirements — mechanical, thermal, chemical, or electrical? Is a shrinkable or non-shrink solution needed? How will the tubing be installed? What is the budget for the project?

With an extensive background in materials and design, Electrolock will use the acquired information to create a custom spiral wound tubing solution to fit your application and budget. Much of this flexibility and adaptability rests on Electrolock’s ability to work with a wide range of spiral wound tubing materials to provide optimal answers.

Let’s briefly examine those material options.

Aramid Paper/Nomex®

Used as a dielectric insulator for high-temperature systems, aramid paper is lightweight, durable, and provides heat and flame-resistant performance in many industries. Nomex, specifically, provides thermal and electrical insulation up to 220°C.

Polyimide/Kapton®

Due to its large range of temperature stability and its electrical isolation ability, polyimide film is used in electronic manufacturing as an insulation and protection layer on sensitive and fragile components. Polyimide films offer high dielectric strength and thermal performance up to 230°C.

PET (polyester)

A polymer resin of the polyester family, PET (polyethylene terephthalate) provides physical toughness and electric resistance in an easily heat-shrink film. Polyester films offer high dielectric strength but are limited to about 130°C thermal applications.

PEEK (polyether ether ketone)

PEEK films are a good combination or middle ground between polyimide and PET, offering high dielectric strength and good thermal performance. Also FDA compliant, PEEK film has good chemical resistance and inherently low flammability.

Fiberglass

Fiberglass provides strong reinforcement, a low thermal coefficient of expansion, and very high thermal performance of up to 600°C. It is often used as part of a tubing solution when weight isn’t a primary concern.

Felts

Felts offer low thermal conductivity and can be made with different core materials such as glass, Nomex, or polyester.

Foils

Both copper and aluminum foils are available in various thicknesses to add different characteristics to custom spiral wound tubing.

PTFE/Porex®

Electrolock has teamed up with Porex to form continuous spiral wound tubing reflectors for inline installation on UV-equipped systems. This proprietary PTFE is highly reflective and maintains performance in temperatures up to 260oC.

Use Spiral Wound Tubing Materials to Craft Ideal Solutions with Electrolock

Beyond the scope of materials, Electrolock’s expertise can be tapped into for value-adding options in tubing installation. For instance, Electrolock offers special configurations that can be used to ease installation, enhance the application, or amplify the efficiency of spiral wound tubing:

• Cut to length parts
• Flared ends
• Sealed end caps
• Notched cuts
• Angle cuts
• Punched holes
• Continuous length tubing

Variable tubing dimensions are variable and altered to fit specific requests. In general, tube length is produced from as little as .500 of an inch to continuous length. Wall thickness ranges from .002” to .125”; Inside diameters come in measurements from 0.50” up to 6 inches.

Further engineering assistance is provided after the tube is made. Electrolock has full in-house testing capabilities to validate all the performance requirements. As your partner, our team will be present at your facility during trials to ensure the performance of your application.

Further design enhancements add a variety of high-performance applications, including (but not limited to):

• Thermal cutouts
• Slot liners
• EMI shielding
• Under the hood heat shields
• Battery and capacitor sleeves
• Corrosion prevention
• Bolt insulators

Electrolock has produced premier insulation products, including the use of many spiral wound tubing materials, for the high voltage electrical, thermal insulation, and battery industries for more than 60 years. We have deep experience in working with any material to solve insulation challenges.

Electrolock’s focus has always been on creating bespoke — unique, tailored to each client — answers to service the most technically demanding requests. So you won’t simply pick a product from a catalog; you’ll work with Electrolock’s team to create a custom-designed answer to your particular problem.

Contact Electrolock today to schedule a one-on-one consultation or evaluation on your material needs or application specifics.

The push for the electrification of vehicles has created a rapid acceleration of the use of Lithium-ion (Li-ion) batteries and is expected to expand the market in this realm to more than $9 billion by 2024 with a projected compound annual growth rate of 34%.

Given the expected growth in the use of Li-ion batteries, the industry is continuing to focus attention on measures designed to reduce any potential for dangerous thermal runaway conditions. Thermal runaway events are particularly dangerous for Li-ion batteries, given the notorious nature of combating fires involving them.

What is Thermal Runaway?

In the simplest terms, thermal runaway begins when the heat generated within a battery exceeds the amount of heat that is dissipated to its surroundings. If the cause of the excessive heat creation is not remedied or curtailed, the condition will worsen. As the internal battery temperature rises, the battery current will also rise — which in turn causes more heat. This results in a domino effect, and thermal issues in a single cell can begin to affect other batteries in close proximity (or part of the same pack). Once underway, thermal runaway is difficult to control and rein in.

Whether caused by defects, mechanical failures from damage, or improper operation of the system — such as storing batteries in a climate with temperatures outside the recommended range — thermal runaway will eventually drive up temperature and pressure until the battery cell ruptures. If left unchecked by built-in system protections or a Battery Management System (BMS), thermal runaway can cause a fire in affected and adjacent cells and send a bad situation into dangerous or disastrous territory.

Given the nature of battery construction, with extremely limited space for insulation protection, what are the best options for reducing cell-to-cell or module-to-module flame spread? How can the extreme heat from one cell be limited in spreading to the adjacent cells or other modules in the pack? How do you stop the chain reaction of thermal runaway once a single cell vents or ruptures?

Battery Thermal Runaway Insulation Solutions from Electrolock

Electrolock supplies various thermal runaway insulation materials that limit the spread of flame and heat during a thermal runaway event. As with all of our battery insulation material choices, our engineers try to understand the requirements of your specific battery pack and try to choose the best options for testing in the limited space available.

These materials can be a combination of flame and thermal barriers or strictly a thin wall, flame resistance part. After you test and approve the material options, we can provide the finished parts fabricated to the required dimensions. Electrolock has a half-dozen specific solutions using Pyrel-Therm and Pyrodox, a pair of thermal protection materials.

• Go-Therm Thermal Runaway Barrier– This highly flexible, silicone-based barrier is designed to be used as an interior lining of the battery case. It offers superior performance to protect the pack from the ejecta and flame caused by thermal runaway. GO-Therm is designed to be a flexible option to rigid mica plate. GO-Therm Battery Pack Thermal Runaway Barrier can be used to line the interior of a battery pack or can be used as a thermal runaway barrier between prismatic cells in a module. Parts can be fabricated to size and are available with a pressure-sensitive adhesive on one side.
• Pyrel-Therm EIG 1000 — This thin high-temperature thermal insulation material is designed to meet extreme heat environments with excellent thermal resistance, extremely low shrinkage, low thermal conductivity at high temperatures, and excellent compression resistance. EIG 1000 is available in master widths up to 1016 mm as well as custom widths and punched shapes.
• Pyrel-Therm ES 1100 — This material mirrors many of the benefits of EIG 1000 — tremendous thermal resistance, low shrinkage, and low thermal conductivity — with the added bonus of excellent mechanical properties. ES 1100 is available in master widths up to 1220 mm as well as custom widths and punched shapes.
• Pyrel-Therm RMC Mica Heat Shield — Designed to meet the demands of extreme heat environments, it exhibits a very low heat transfer profile and serves as an effective dielectric and gas barrier. RMC Mica Heat Shield is available in master rolls up to 1 meter wide or in custom slit or punched parts.
• Pyrodox GP 500 Mica Cable Tape — This is a special heat-treated phlogopite mica cable tape with a silicone binder and fiberglass backing. The tape is engineered to withstand extreme electrical and thermal overloads as well as high moisture environments, which permits its use in cables having extended fire survival time. Applications include fire survival for control and power cables, mass transit, aircraft, oil well, thermocouple, appliance wire, and shipboard cables. Tape is provided in slit pads or traverse packs in lengths according to the customer’s request.
• Pyrodox HP5 Mica Plate — This mica plate is designed for high-temperature insulating applications and comes with excellent mechanical, electrical, and thermal characteristics including a flame classification of UL 94 V-0. Standard thickness is .1mm-1.9mm, and standard sheet sizes include 1000mm x 600mm, and 1000mm x 1200mm. Both phlogopite and muscovite versions are available.

Electrolock is Your Battery Insulation Expert

Electrolock has been engineering solutions for high-voltage electrical, battery, and thermal insulation industries since 1957. Electrolock’s focus has always been on creating bespoke — unique, tailored to each client — answers to service the most technically demanding requests. You won’t simply pick a product from a catalog; you’ll work with Electrolock’s team to create a custom-designed answer to your particular problem.
Our expertise is trusted by many customers across many fields, including the U.S. Military, which has relied on our battery thermal runaway insulation to safeguard the many battery needs of active service members.

Contact Electrolock today to schedule a one-on-one consultation or evaluation on your material needs or application specifics.

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Let’s examine the aspects of rotary die cutting, and why it makes sense as a manufacturing method for insulation solution — complete with a specific example drawn from the suite of services offered at Electrolock.

What is Rotary Die Cutting?

A die, in the simplest terms regarding manufacturing or crafting, is a tool used to cut material into a given shape. Die-cutting is a fabrication process that uses specialized tools to convert stock materials into custom shapes and designs by cutting, forming, and shearing products from sheets or rolls of materials.

There are also several different types of die-cutting processes available, including digital die-cutting, flatbed die cutting, and rotary die-cutting. Flatbed die cutting uses a flat cutting press and custom steel dies to convert the material into shapes and designs. This process is utilized for thicker materials, larger parts, and for short production orders or small orders. Digital die-cutting eschews dies altogether, and instead uses computer-guided lasers and tool bits to provide the cuts. This process will have high tolerances for more intricate design patterns and is best suited for small production runs or prototyping as it doesn’t require new die components to test out new designs.

However, rotary die cutting offers the capabilities needed for custom insulation solution manufacturing. This process works by employing a custom cylindrical die (or multiple dies) to cut against a hardened anvil roll with the material to be cut and formed passing between those two components. When you need high precision and accuracy in your application and will have a high-volume production run, this method is the best option.

In the pursuit of both precision and speed, rotary die-cut custom insulation solutions provide the most efficient path forward. Rotary die cutting provides uniformity for complex shapes, which are often needed when dealing with the many kinds of materials used in battery insulation applications. A rotary die-cut fabrication process can create many cuts of any given material that are consistently within tolerance limits, which is essential to every manufacturing project. With the design engraved into the die, parts are easily reproduced and the precision in this process also reduces material waste as the die-cut designs can be more tightly placed together.

Rotary dies can be swapped out within presses, which shortens the downtime between different designs and processes. Rotary dies can also handle multi-layered materials and complex designs. For example, multiple materials can be laminated together and die cut at the same time, or sensitive adhesives can be applied so die-cut parts can be supplied on a liner — all of which saves time and money. Rotary die-cut fabrications are ideal for engineering, which needs layers of different materials to be precisely the same size.

Want to know more about Electrolock? Read about their engineered solutions here.

An Example of a Rotary Die Cut Custom Insulation Solution

A good case in point of using rotary die-cutting in practice at Electrolock involves the production of Top and Bottom Cell Insulators, which are just one of the many solutions available in the realm of battery insulation.

These dielectric barriers are designed to protect individual cells, and for cell-to-cell protection, with thin wall die-cut pressure-sensitive parts made of flame-retardant films or papers. Depending on the material used, up to 15 Kv protection can be achieved. An array of materials can be used — such as fiberglass, PTFE, Polypropylene, or PET insulations — and all materials can be instituted with or without adhesive.

Rotary die-cutting is a strong choice for this manufacturing solution due to the uniformity required for each of the specific units. Rotary die cutting also enables that precision to hold through the many different types of material that may be implemented, and — with the possible addition of adhesives — the ability to address or cut and form more than one layer of material at a time. Top and Bottom Cell Insulators are one of the rotary die-cut custom insulation solutions available.

Electrolock Offers Much More

Electrolock has been engineering solutions for the high-voltage electrical, battery, and thermal insulation industries since 1957. Our focus has always and will continue to be, focused on creating bespoke — unique and tailored — solutions to service the most demanding requests.

By choosing Electrolock, you won’t simply be picking a product from a catalog or menu of options. You’ll work with Electrolock’s experienced, expert-level team to create a custom-designed answer to your particular problem.

By collaborating with your business, Electrolock will design, fabricate, and then fully test potential solutions. By validating — through an extensive in-house testing system — before entering production, Electrolock is able to save both time and expense on the back-end of a project.

No matter what your material or insulation challenge, Electrolock will help you solve it.

Contact us today to schedule a one-on-one consultation or evaluation on your material needs or application specifics.

The case study below provides a unique look into the process of developing a product for a customer with a specific end goal. From conception, through testing all the way to implementation and mass production, we take pride in carrying each project through to the finish line.

Who is the Customer?

The customer is a mid-sized electronic components manufacturer looking for an automatable solution that would allow them to insulate a battery housing for one of their products. They have been using a manual process to add the necessary dielectric insulator to the housing since inception, but the labor has grown costly and slow creating a bottleneck in production. The most important factor driving them to seek a process change is a need to improve the line speed and production numbers for this product in order to keep up with demand. A common challenge to be sure, and one we can all empathize with. How do we keep up with demand in a profitable and sustainable way?

The process engineer from the company began looking for ways of improving their throughput. They reached out to a handful of vendors they had worked with in the past or met through the last tradeshow. One of those companies was Electrolock, from whom they had been purchasing other insulation materials for a few years.

Taking the first step

The conversation with the Sales Engineer is the first step in the process and a crucial one. The viability of a product or process needs to be determined early on. The application demands need to be discussed along with any restrictions and expectations in order to determine if a project is even feasible, given our capabilities. Once that has been established the next step is determining what the customer’s budget is for this particular application. This early on in the process, that can be hard for some customers to work out. We try to help by aligning all of the variables and any current costs associated with the current process. For other customers, the budget is a firm, immovable number. In the end, the budget discussion allows us to make better decisions and focus on the sustainability of the solution to be developed. As the old saying goes, we don’t want to design a $5 fix for a $0.02 problem. That helps nobody. Much like the budget discussion we also need to know rough annual consumption information to ensure we develop a solution that makes sense for the demand and budget.

With that first discussion completed, we both have a clear picture of the target and goals and can get to work on understanding what our options are. A call with our engineering team is a great way to dive into the technical details, begin considering material options, and really filling in the picture that will guide the rest of the process. The budget and technical requirements of the product really help us focus on the appropriate material to accomplish the goal. In this case, a simple, common polymer film seemed an adequate, reliable, and affordable solution for the insulating cover, meeting the dielectric strength requirement and a durability requirement that came out of the engineering brief. The question now becomes, how do we automate its application without designing some exorbitant custom machinery? We decided a continuous shrink tube would be a likely solution as it could be fed from a roll into an assembly line directly onto the housing, cut to size, and passed through a small oven. A mechanically bonding solution that provided nearly double the necessary insulative properties and would also fit within the budget. The problem? A tube of this particular material at the required size and thickness wasn’t available off the shelf. It would need to be made in-house, out of flat film.

Getting to Work

Luckily this is right up our alley. We have been converting flat films and papers into tubes for decades, though not this material and size combination. We offered to make up some samples for the customer in exchange for a scheduled test in which we could get some feedback on the performance. The customer agreed and within a week, the samples were manufactured and shipped to the customer’s manufacturing facility. We provided three different types of the tube made in slightly different ways so that we could optimize the fit, application, and performance to meet or exceed those requirements set in the review call. One of our Sales Engineers visited the customer’s facility to discuss the results of the tests and was pleased to find out that 2 out of the 3 samples met or exceeded the performance requirements and the customer was excited with the performance of one sample in particular. In the test, the application of the tube onto the housing was effortless and the tube shrunk perfectly onto the housing with precision. This was a clear winner.

The following week the customer requested a small batch of the chosen sample tubing. They wanted to test it in an automated process, so they requested several hundred feet. We agreed on a price for the trial material and samples were made and shipped. During this time, we worked with the customer on locking down estimated volumes and pricing for the tubing including lead-times and production capacity. We came to an agreement that based on the findings of the trial, we had created an effective solution and that the customer would purchase a primary ship-set for manufacturing implementation. All dimensions and packaging were discussed to ensure all expectations were met. The trial completed successfully, and the customer agreed to make a primary ship-set purchase with a 4-week lead time. A spec was drawn up, materials ordered, and manufacturing scheduled.

Once the first ship-set had been manufactured, our Sales Engineer visited the customer’s facility for the first day of production to ensure he was available and on-site should they encounter any difficulties that didn’t present during the tests or trial. As expected, all went well, and the customer is using the solution successfully to this day.

Electrolock has been supporting the electrical industry in a wide range of applications for the better part of the last century. We are the most innovative and trusted problem solvers in the electrical and thermal insulation industry. When others give up, we get started. Tell us about your unsolvable problems and we are sure to come up with an elegant solution that not only works but fits your project requirements and budget.

Tell us about your challenge!

Below is a breakdown of the types of mica used in modern coils, written by President of Electrolock, Joe Williams III.

Types of Mica Typically Used in Medium and High Voltage Coils

Nearly all medium and high voltage coils use muscovite mica because of its higher electrical purity. Most muscovite mica (and I would argue the best muscovite mica) comes from India. There are two ways to process the original chunks of muscovite mica: a calcined process and an uncalcined process. Both mica processes produce high voltage mica tapes that exhibit high breakdown voltages, good voltage endurance, and low dissipation factors. While both tapes have sufficient electrical properties, in general, calcined muscovite exhibits slightly higher breakdown, and uncalcined muscovite mica typically has greater voltage endurance.

Calcined Muscovite

In the calcined process chunks of flake muscovite are passed through a high-temperature rotary kiln (sometimes called a rotary calciner) and the tumbling heat breaks some intermolecular bonds exfoliating the flake and allowing for various mixing equipment to produce very small mica flakes. These tiny, calcined muscovite flakes have a very small diameter to thickness ratio. When made into a paper and then high voltage ground wall insulation the calcined mica paper tapes exhibit a high voltage breakdown.

Uncalcined Muscovite

Under the uncalcined process the chunks of flake mica undergo an ablative process of high-pressure water jets that break up the rock in small mica flakes with a high diameter to thickness aspect ratio. These flakes are then screened and segregated by size to assure a consistent mica paper with the proper aspect ratio of flake diameter to thickness. Mica tapes made with uncalcined mica paper exhibit longer voltage endurance because of the longer tracking path around the larger aspect ratio flakes. There is also more mica per given thickness when compared to calcined papers.

Popular Uses

It should be stressed that you can make very acceptable high voltage insulations with either mica tapes but they do have their preferred intended uses. Calcined mica is generally preferred in medium voltage vacuum pressure impregnation coils and is often made with higher binder contents. In medium-voltage coils impregnation is easier because of the lower insulation builds. The calcined mica tapes with higher binder content are more durable, easier to tape, and voltage stress is typically much lower making voltage endurance requirements easier to satisfy. Calcined muscovite mica is also preferred in most resin-rich tapes for both medium and high voltage coils because the smaller aspect flakes are less susceptible to blocking in self-wound resin-rich tapes.

Uncalcined mica tapes are predominantly used in the high voltage vacuum pressure impregnation process. These uncalcined mica tapes are typically made with very low binder contents around 8% by weight. These low binder tapes are more fragile and typically applied with robots where the taping tension and taping angles are more controlled and consistent. The advantage of the low binder high aspect ratio mica flake tapes is their easier impregnation through thicker ground walls and higher voltage endurance when voltage stress is greater. There are new resin-rich tapes on the market taking advantage of the increased mica to thickness ratio, however as mentioned blocking can be a topic, so it is very important to take special care during manufacturing and taping.

Both mica tapes have been used successfully for decades in many different applications and designs. Understanding the slight benefits of each can help distinguish which might be best for your specific application.

Be sure to check out our product offerings for motor and generator coils as well as our wire and cable tapes.

If you have any questions about the content in this article, drop us a line and we would be happy to discuss it with you.

Engineers come to Electrolock with some of their biggest and most complex electrical insulation challenges, and they trust Electrolock to develop quality solutions. A big reason for that trust is because of the thorough testing and validation procedures we undertake in our labs. We’re able to run the final products through a battery (pun intended) of tests depending on the unique needs of each solution. It’s a combination of expertise and high quality lab capabilities that come together to give engineers the peace of mind that the Electrolock solutions will stand up to the demands in the field.

Batteries power so many of the devices and equipment we rely on every day. Few, however, face the demands of those placed on them like batteries used by the military. Today’s soldiers rely on batteries to power their equipment in extreme and often dangerous conditions. Military battery manufacturers rely on Electrolock’s engineers to deliver solutions to their materials needs. Learn more about how Electrolock provides custom insulation solutions for critical military applications.

To learn more about the breadth of Electrolock’s battery insulation solutions, visit Battery Insulation Solutions.

The current Polyimide Film supply shortage is the result of significant demand from flatscreen electronics manufacturers. The thermal transfer properties of modified Polyimide Film make it perfect for use in LCD screens and other similar electronics applications. Supply issues have affected lead times and pricing, causing interruptions throughout the market.

Despite the widespread Polyimide Film shortage, Electrolock is able to meet demand in a timely manner. We’re confident in our continued ability to supply Polyimide Film for both existing and new applications. Further, Electrolock’s engineering team is ready to assist with solution design, application testing, process integration, or any other materials engineering needs.

Organizations with immediate or upcoming Polyimide Film supply needs should contact Electrolock asap.

For 5 years, Electrolock has exhibited at The Battery Show in both Europe and the U.S., and we’ve witnessed change in this fast-moving industry. At this year’s show, electric motor design and optimizing the electrification of vehicles attracted the most attention.

In the past, conversations about battery technologies dominated this show. And yes, investments in battery advancements certainly continue, including those to deliver improvements upon existing technologies, like longer battery life and faster charging. However, much of the focus this year centered around electric vehicle design, including the battery pack (safety), the electric motor (hairpin conductors), and the complete electric drive system.

As it relates to electric motors, significant resources are being invested towards new innovations to deliver more power, specifically in hairpin motor designs and technology. The transition from random wound motors to hairpin motors dominated our conversations on the exhibition floor this year. Roughly three-quarters of the visitors to our booth wanted to discuss slot liner design for hairpin motors and the insulation used on the hairpin wire itself. There is a drive for optimizing copper slot fill and the coinciding increase in power from the motor.

Many engineers are moving away from random wound motors to take advantage of the shape of the hairpin wire, optimizing the amount of copper that can fill the slot. A primary objective is to get more power from electric motors, particularly in the EV market. At Electrolock, these conversations focus on introducing slot liners into the production process, which represents a huge opportunity for our customers.

Electrolock’s engineers are experiencing this shift in power first-hand. Our slot liner solutions and hairpin wire coatings help our customers achieve greater performance. Working in the field and on the production floor is what enables our engineers to come up with new solutions before the client asks, “how can we get even better?”

To learn more about our custom materials engineering processes, click HERE.

So much of what goes into the end result of a product stems from what happens during production. Testing, validating, and perfecting a process over time is something our engineers take with a hands-on approach. This is evident with our PVF shrink films, a tailored approach to high performance sacrifice and release films for high voltage coil production. It’s this intentional side of process development that we believe makes the difference to our customers.

Process aids, such as specialty shrink films, make a monumental difference in the manufacturing of high voltage coils and composites. While there are many release coatings, Electrolock offers one that is unique: a non-dispersion, PVF film coating. This customized coating is applied to our heat shrinkable polyester film to create a smooth, easy release from the cured composite.

Practical Applications

Polyshrink PVF-series shrink films combine the shrink properties of Electrolock’s standard Polyshrink tapes with the high-temperature release attribute of PVF. The compression force characteristic of our polyester-based films makes for an effective and useful tool for consolidating and compressing electrical coils. They are commonly used as a sacrifice layer to compact the pre-consolidated coil or the finished high voltage hot pressed coils, producing a consistent corner radius. These customizable shrink films are available in 2-mil thickness and slit to custom widths.

The advantage of PVF coating is a solid, high-temperature release film. The maximum temperature of our Polyshrink tapes is 160°C. Electrolock’s Polyshrink PVF release tape can accommodate up to 185°C. This higher temperature release is especially important in application that don’t have precise temperature control. The result is an even, clean release from epoxy composites even with extreme temperatures. It allows the tape to release in one continuous wrap. There is zero transfer of the release coating to the underlying composite part, leaving a clean, consistent surface finish.

Contact Electrolock today to learn more about Polyshrink PVF and to request a sample.

Electrolock understands that your company’s needs are unique. Our approach begins by defining your requirements. We work with your engineering group to understand your application, how the product will be processed, and what cost requirements we need to meet. By following this process, we eliminate the trial and error often required with off-the-shelf products.

Once we understand your application, Electrolock uses our extensive background in materials to custom design a tube to fit your application and budget. Materials like PET (polyester), Kapton® (polyimide), Nomex® (aramid paper), aluminum, fiberglass, felt, vulcanized fiber, and mica are a few of the options that can be considered to manufacture a tube.

An additional benefit of working with Electrolock is the engineering assistance we provide after the tube is made. Electrolock has full in-house testing capabilities to validate all the performance requirements of the tube. Tests include electrical, thermal, mechanical, and chemical resistance. As your partner, Electrolock’s engineering and sales teams will be present at your plant during trials to ensure the tube works correctly in your application.

Electrolock already provides tubing for a variety of high performance applications. Each of these tubes meet our customers specialized design requirements. These applications include:

• Thermal cutouts, heating elements, slot Liners, motor lead insulators, sensors, EMI Shielding, and speaker voice coils.
• Under the hood heat shields and caps and exhaust systems.
• Battery and capacitors sleeves, current collector sleeves, corrosion prevention, masking caps, protective liners, bolt insulators.

So why not cut out the trial and error and partner with Electrolock to develop a tube that is a perfect fit your application.

For more information or to learn more about our process, click here.

In a new paper published in the IEEE Transactions on Industry Applications, researchers compared using flat wire hairpin winding and stranded round wire in some of the most common motor technologies found in EVs: induction, synchronous permanent magnet, and wound field machine topologies.

Read the Charged EVs article about how Tecnomatic uses innovative designs in hairpin stator systems to reduce heat and improve torque in EV traction applications. Similarly, Electrolock has developed a custom slot liner that also helps maximize the amount of copper in the slot resulting in more horsepower.

Optimizing slot liner design can help create the most power from your hybrid electric vehicle (HEV) or electric vehicle (EV).

One of the biggest challenges for the HEV/EV manufacturers is how to achieve more horsepower from the same size motor. How do you optimize the amount of copper used by the hairpin coil in the slot?

We took this challenge to our Electrolock engineers who created a custom slot liner solution. Designed using the thinnest wall thickness while still performing at a high level, our slot liner allows manufacturers to maximize the amount of copper used in the slot.

Currently, many motor manufacturers, using hairpin coil designs, are insulating the slot with traditional slot liner shapes and materials (S, B and U shaped insulation). Both manufacturing and electrical challenges arise from this style of slot liner. Not only are these designs difficult to insert into the slot, but after insertion, the slot liner does not hold its shape, making it difficult to insert the conductor. These traditional slot liner options are also the leading cause of electrical failures: shorting between turns or to the slot wall.

Frustration, high scrap rates, low productivity. Sound familiar?

Electrolock’s slot liner solution is custom designed to meet all of your electrical requirements (dielectric breakdown and partial discharge inception voltage), your temperature requirements (Class H or higher) and your mechanical requirements (abrasion resistance, bond to the slot wall and to the conductor). It meets all these requirements while also providing the thinnest insulation design.

Bottom line: we make custom products that will work in your existing system. Getting in the trenches with your engineers to understand exactly what you need is the first step toward a better solution. As a result, we understand how the product will process, the performance requirements, and what it needs to cost to execute this next-level design.

As with all products we supply, Electrolock can test on site. Doing so gives you the confidence that our custom solution will perform the way it is designed.

See the difference. Watch our custom slot liner design in action HERE.

Check out our WEBSITE for more information or call a product expert today at 440-834-7500.

Electric generators require some repair as the rotor ages, including turn-to-turn shorts, field grounding, thermal failure, contamination, retaining ring failure, or creep from centripetal forces in the winding. Copper turn shorts can result from insufficient bonding of the rotor turn insulation to the copper. Electrolock tests the thermal aging properties of rotor insulation during the qualification process and applies a special adhesive system to provide the proper bond to copper turns. Rotor turn shorts can produce enough heat to melt the rotor.

Rotorsproduce very large centripetal forces, creating strain and compression on the turn insulation. There can be vibration and copper movement as the winding thermally expands under load. The adhesion of the insulation to the copper is critical to maintaining the dielectric barrier throughout the operating cycles of the generator. There are cooling slots in the copper turns that must remain clear when insulated with pre-slotted rotor insulation. These slots must be fabricated precisely to match the slots in the copper winding. Electrolock considers all these factors in the design and manufacturing of rotor insulation to provide our customers with continuous operating success, avoiding copper turn shorts, or blockage of vent holes.

Electrolock’s Pyrodox Cable tapes offer the design engineer the unique high temperature features of thin inorganic mica paper bonded with silicone resins to a strength member of glass, polyethylene, or polyester film. These tapes can be precision slit to widths of less than 200 thousandths of an inch and spiral wrapped on wires as small as 22 gauge.

Pyrodox cable mica tapes have been used in UL 5107, UL 5128, and UL 2196 high temperature cables for applications in high temperature appliance, igniter cables for furnaces, thermocouple cables, and other high temperature cable applications. They are also used in military shipboard cables where low smoke halogen free cables are required.

Pyrodox cable tapes are available in widths as thin as 3 mils and are provided in slit pads or traverse wound spools. Traverse wound spools provide manufacturers with long continuous tape lengths without bulky, pressure-sensitive tape splices that can create a bulge in the insulation wall. These long continuous lengths significantly reduce taping machine down time.

Electrolock provides insulation solutions tailored to meet your needs. Read industry and company news, and learn more about featured products in our collection of informative blog posts below.