Electrical Insulators
Die-Cut Insulators were one of NEDC first products. This product line went along with gaskets as some of the first parts NEDC cut for customers. When NEDC first started, most electrical insulators were die-cut. However, with the new machinery that NEDC employees, waterjet, laser, and other machines also play a part.
Materials
Many of the materials used for electrical insulation are also used on our other products. In other words, gaskets, and thermal pads may also isolate an electrical current. As a result, materials including plastic, thermal interface pads, rubber, and paper like products all may have the ability to be electrically isolating.
Thermal Pads
One of NEDCs core products are thermal pads. For that reason, its interesting that thermal pads oftentimes serve as electrical insulators. Products such as Sil Pad®, and Gap Pad®, are marketed because of their high volume resistivity making them ideal for electrical insulation while providing a thermal management solution.
Many Gap Pad® products offer electrically insulating properties. Gap Pad® products such as GPVOUS, GPVOS, GP5000S35, GPHC3.0, GPHC5.0 offer high levels of electrical insulating properties. This is in addition to their thermally conductive properties as well.
Many Sil-Pad® products offer electrically insulating properties. Sil Pad® products that are electrically isolating include Sil-Pad 900S, Sil-Pad 2000, Sil-Pad 400, and others.
Thin Plastics
Many thin plastics that NEDC cuts are electrical insulators. Materials like Kapton®, Mylar®, Lexan®, Formex®, G10/FR4 Epoxyglass all may serve as electrical insulators. These plastics can be converted into die-cut insulators.
Mylar® is a polyethylene terephthalate(PET) that is registered by DuPont. These materials usually come in thin films ranging from .002” to .014” in thickness. It is commonly used as an electrical insulator. MYLAR® A is the most common type. Mylar® MO is approved for Class B insulation.
Kapton® is a polyimide film that is registered by DuPont. This plastic can be certified to MIL-P-46112 Type 1, and ASTM D5213 Type 1 Item A. It usually comes in thin formats such as .0005” to .005” in thickness. Anything above this enters into the category of Cirlex®. Common applications include insulation blankets, and insulation tubing. There are a few different types of Kapton Film besides Kapton HN. These include Kapton® FN, Kapton® FWR, Kapton® GS, Kapton® MT+, and Kapton® RS.
Lexan® is a polycarbonate plastic that is oftentimes die-cut in film form. Lexan® plastic is a registered trademark by SABIC. Lexan® is extremely tough, but is formable. There are many different types. However, NEDC mainly die-cuts 8010, FR700, and others.
Formex® is a flame retardant polyproylene plastic. Formex® has excellent electrical properties. This plastic is fungus inert. There is GK-5, GK-10, GK-17, GK-30, GK-40, and GK-62. These plastics run from .005” in thickness to .062”.
Epoxyglass/G10/FR4 is a plastic like material that is really laminated glass with epoxy bonding it together. These materials are oftentimes used as electrical insulators. Most often NEDC die-cuts these materials, the thickness is below .015”. G10 is generally not thought of flame retardant. However, FR4 is flame retardant. MIL-I-24768 encompasses many different options. G10 being /2, and FR4 being /27. These materials are generally available .005”-many inches thick.
Rubber
At NEDC we cut many rubber materials to make gaskets. However, rubber materials can also sometimes serve as electrical insulators. For example, silicone rubber is a great electrical insulator that is commonly used in cables or wiring. Some other rubber materials used for electrical insulation include fluorosilicone, neoprene, EPDM, or urethane.
Silicone Rubber is commonly used as an electrical insulator. In fact, this material is probably the most commonly used material at NEDC. We use silicone rubber for gaskets, insulators, vibration dampening, and many other uses. Common certifications include A-A-59588, ZZR765, and others.
Fluorosilicone Rubber is another commonly used electrical insulator. However, it is not as commonly used as silicone because of its other qualities that tend to make it more expensive. Some specifications include MIL-R-25988, AMS-3329, and others.
Neoprene Rubber is a synthetic rubber also another commonly used electrical insulator. It is used in cable jacketing for wire and cable. It is often flame resistant.
Paper like Products – Die Cut Insulators
Many paper like products serve as electrical insulators. Some common ones that NEDC sees are Nomex®, Fishpaper, Kraft Pulp, and others.
Nomex® is a aramid fiber paper. It has a high dielectric strength. This paper is used for The most common type of Nomex® is Nomex 410. Nomex 410 comes in a number of thicknesses ranging from .002” to .030”.
Fishpaper is an electrically insulating paper that is resistant to heat. It is an excellent insulator used in fuse tubes, and electronic devices. Thicknesses of fishpaper range from thin (.005”) to thicker (.030”). Specifications include MIL-I-495. It mostly comes in dark colors such as gray, or dark blue.
Electrical Qualities to look for with Die-Cut Insulators
Volume Resistivity
Volume Resistvity plays a huge part in die-cut insulators. The higher this number the better. A low number indicates the materials conductivity. This number indicates how much the insulator resists electric currents.
Dielectric Strength
Dielectric Strength is an important metric with die-cut insulators. It helps determine the quality of the insulator. It is defined as the maximum voltage required to produce dielectric breakdown through the material. All the materials above would register a high dielectric strength, for example.
Conclusion
As with most materials NEDC provides, adhesive backing is available on certain products. Some common tapes we use from 3M are acrylic based 9485PC, 9472, 467MP, and 9469PC. For more information on electrical insulators, or you believe you have a project that could use a die-cut insulator, please contact sales@nedc.com.
Electrical Insulators Blog
Frozen Epoxy Films in Stock at NEDC!
NEDC is a converter of frozen epoxy films to make custom preforms for customers to buy. For that reason, NEDC has many frozen films in stock. These include: Ablefilm 5025E Ablefilm 561K Ablefilm CF3350 Ablefilm 566K And others. We wanted to just get it out there on...
Previous Posts
Garlock BLUE-GARD Gasketing Options | Waterjet/Die-Cutting
At NEDC, engineered options are our thing. In this blog, we wanted to...
R10400M (Medium) Flame Retardant Silicone Sponge | Custom Die-Cut Parts
Silicone Sponge, and Silicone Foam are different. I’ve talked about that...
Thermal Pad Tackle Box | Sales Tool for Testing/Sampling
At NEDC, we are all about thermal. We enjoy making new sales tools to...
Sil-Pad A2000 aka SIL PAD TSP A3000 | Custom Die-Cut Thermal Pads
At NEDC, we die-cut a lot of thermal interface materials (TIMs). Cost is always a concern when customers are selecting thermal pads. When selecting an .015’’-.020’’ thin thermal pad, Sil-Pad A2000 is a good choice. Why Select Thermal Interface Pad Sil-Pad A2000? I’m...
Thermal Pad Sample Kit 2.0 | Sil-Pad & Gap Pad in One Kit
During COVID, NEDC released a Thermal Pad Sample Kit. It had a number of Gap Pads on it. We decided to re-release it- new. and improved. Why Thermal Pad Sample Kit 2.0? This time it has a combination of Sil-Pad and Gap Pad on the Thermal Pad Sample Kit. It has...
Electrical Enclosure Gaskets | Custom Die-Cut | Silicone, Neoprene
At NEDC, we make gaskets for all types of projects. One of the most common types of gaskets we make is something we call enclosure gaskets. We call them electrical enclosure gaskets here because oftentimes the enclosures that we are sealing off house electrical...
Weatherproof/Weather Resistant Gaskets | Outdoor Gaskets
At NEDC, we discuss types of gaskets with customers all of the time. It can range from high temperature gaskets, to fuel resistant gaskets. In this blog, we wanted to discuss weather resistant gasketing materials. Another thing I’ve heard customers called weatherproof...
3M Thermal Interface Pads | Silicone – Acrylic | Die-Cut Thermal Pads
At NEDC, we cut thermal pads on a frequent basis. Customers come all the time, asking for a thermal interface pad for their special electronic, phone this, defense system that. With all of these commercial electronics, and military applications, you need a reliable,...
Kalrez Perfluoroelastomer | Custom Die-Cut Parts
At NEDC, we have many materials to choose from when a customer discusses an application. For todays blog, I thought I’d write about an extreme material. Why Choose Kalrez® Perfluoroelastomer? The answer to this one is simple. If you have an application that requires...
Membrane Switch Spacers | Custom Die Cut/Laser-Cut Shapes
If you open up a membrane switch, you will find there are 3M products all over the place. 3M 467MP, 3M 467MP liner- any die-cutter who is worth their weight knows 3M 467MP is a commercial staple for this reason. NEDC provides all sorts of insulators, and spacers for...
Ultem Film | PEI Film | Custom Die-Cut Electrical Insulator
NEDC manufactures ( by die cutting) electrical insulators/isolators for many customers. One of the more robust electrical insulators/isolator around is Ultem™, or PEI. Properties of Ultem/PEI Film Ultem/PEI is a thermoplastic material. Ultem™ offers high heat...
9485PC Adhesive Transfer Tape | 350 Acrylic Adhesive | Custom Die Cutting
NEDC laminates many tapes to many types of gasketing materials. However, not all tapes are just adhesive laminated onto a kraft liner, and done- some adhesives are reinforced with fiber to make them more manageable. One of the tapes that utilize these fibers is known...
Flame Retardant Adhesive Transfer Tape | Lamination, Die-Cutting
At NEDC, we stock a lot of materials that are flame retardant. In fact, we have a page that just mentions all the flame retardant materials we have. These include gasketing, thermal pads, absorbers, and other types of materials. One thing we have not mentioned on this...
Custom Dust Gaskets | Foam/Sponge Neoprene, Silicone, & PORON
At NEDC, as a gasket manufacturer we supply a number of different types of gaskets to our customers. When I’m discussing applications, one of my favorites is custom dust gaskets. The reason for this is because Dust Gaskets are usually some of the more simple gaskets....
Battery Cushion Pads | Soft Custom Pads | Foam, Sponge | Custom-Cut
At NEDC, we manufacture a lot of products. Battery Cushion Pads are a common product we make. Customers who are making a modular electronic, oftentimes have a battery that also requires cushioning, or thermal cooling. What are Battery Cushion Pads Used for? Battery...
All of the information presented above is believed to be factual and accurate; however, NEDC is not liable for any design or application utilizing this information.
New England Die Cutting
Capabilities/Products
Quick Links
Popular Blog Posts
Sil-Pad or Gap Pad?
It is easy to understand why the applications of Gap Pad and Sil-Pad can be confused. This is because both thermal pads have a lot of similarities. For the most part Sil-Pads and Gap Pads are electrically isolating. Both thermal pads are thermally conductive, and both...