Dual-Layer Kapton Tape for High-Voltage and High-Temperature Insulation

CASE STUDY

Dual-Layer Kapton Tape for High-Voltage and High-Temperature Insulation

A Customized 65 μm Polyimide Insulation Solution Achieving 8 kV Breakdown Voltage

1. Customer Application

The customer required a high-performance Kapton tape solution for an electrical insulation application involving demanding voltage resistance and high-temperature conditions.

2. Customer Requirements

• High breakdown voltage performance.
• High-temperature resistance requirement: 180°C for 24 hours.
• A customized insulation tape solution capable of meeting the customer's application requirements.

3. Technical Challenge

The existing single-layer Kapton tape had a breakdown voltage of more than 4.5 kV, which did not meet the customer's higher voltage requirement. Existing solutions from other suppliers were unable to provide a suitable solution within the specified timeframe.

4. Innovative Solution: Dual-Layer Kapton Tape

Based on the customer's requirements, LY proposed and successfully developed an innovative dual-layer Kapton tape structure.

The developed tape consisted of two Kapton film layers bonded together using an adhesive layer between the films. The bottom surface of the inner film was coated with silicone adhesive, which served as the bonding layer for attachment to the customer's product.

The total thickness of the developed tape was 65 μm. The dual-layer structure was developed specifically to improve the insulation performance required by the customer.

5. Product Structure

• Outer Kapton Film
• Adhesive Bonding Layer between the two films
• Inner Kapton Film
• Silicone Adhesive on the bottom surface of the inner film for bonding to the customer's product

6. Product Specification

7. Testing & Validation

The developed dual-layer Kapton tape achieved a breakdown voltage of 8 kV, compared with more than 4.5 kV for the existing single-layer solution.

The customer specified a high-temperature requirement of 180°C for 24 hours. The original detailed measurement records for this historical project are no longer available; therefore, this case study does not state a specific measured high-temperature result.

The overall customer validation was successful, and the developed product passed the customer's testing and proceeded to batch orders.

8. Project Result

• Successfully developed a customized dual-layer Kapton tape solution.
• Achieved a tested breakdown voltage of 8 kV.
• Addressed the customer's high-voltage insulation requirement.
• Completed successful customer validation.
• The project resulted in batch orders.

9. Why Choose LY

• Source manufacturer with in-house coating, rewinding, and slitting capabilities.
• Ability to develop customized electrical insulation tape structures.
• Experience in high-voltage and high-temperature insulation applications.
• Flexible technical communication and project-based product development.
• Focus on long-term cooperation and application-oriented solutions.

10. Related Applications

• High-voltage electrical insulation
• High-temperature electrical insulation
• Transformer and motor insulation
• Electronic component insulation
• Customized industrial insulation applications

11. Contact

Changshu Liangyi Tape Industrial Co., Ltd. (LY)
Email: ftrade2@liangyitape.com
WhatsApp: +86 13338711561
Website: electrical-insulationtape.com