7 High-Performance Plastics for Electrical Insulation Applications
Applications or assemblies that involve electrical insulation, high voltages, or sensitive electronics should prioritize plastic parts made from high-performance materials that can withstand their operating conditions and provide electrical characteristics that support application functionality. In order to provide the highest quality solution for applications that require electrically insulating properties, look for materials that deliver the following advantages:
- High dielectric strength and low conductivity
- Resistance to heat, UV, chemicals, and moisture
- Mechanical strength and impact resistance
- Thermoformability for manufacturing
- Hydrolytic stability
What Plastics Provide the Best Electrical Insulation for Industrial Applications?
Electrically insulating plastics offer distinct material properties to meet the requirements of electrical assemblies, components, and electronics. They range from high-performance thermoplastics to natural insulators, providing specific benefits and solutions, including popular materials such as Ultem, polycarbonate, and acrylic.
Ultem
Also known as polyetherimide (PEI), Ultem is a high-performance thermoplastic with a range of favorable material properties. It offers high strength and stiffness, alongside thermal stability, flame resistance, and chemical resistance. For electrical applications and electronics, this material is an excellent choice, delivering a number of required properties for electrical insulation:
- High dielectric strength
- Excellent arc resistance
- Self-extinguishing
- High-temperature performance
- Dimensional stability
PEEK
PEEK, or polyetheretherketone, is an advanced plastic material known for its ability to withstand high temperatures and corrosive chemicals. This high-strength, high-stiffness plastic offers a high strength-to-weight ratio. It maintains its properties under harsh conditions with a low coefficient of friction for sliding characteristics without lubrication. As an option for electrically-insulated applications, PEEK provides material properties that include:
- Superior dielectric strength
- Resistance to chemicals, heat, and wear
- Mechanical strength and dimensional stability
- Low water absorption
Nylon
With a lightweight feel, exceptional strength, durability, and elasticity, nylon offers an effective material for electrical insulation. While it does not provide the same high-heat performance or UV resistance, and may be susceptible to static electricity, this material can be used for various electrical applications. The properties of nylon can prevent the easy flow of electricity through these features:
- High resistivity and low conductivity
- Mechanical strength
- Versatility in dry conditions
- Resists heat up to 509°F (265°C)
Polycarbonate
Polycarbonate is a thermoplastic synthetic resin that can be molded when heated, offering a durable, transparent, and impact-resistant material that is easily machined to project specifications. Compared to other materials, it may not provide as much chemical resistance, and it can be easily scratched due to its optical clarity. However, polycarbonate is still an excellent option that can be used in a variety of electrical applications and electronics, including housings and components, with favorable properties that contribute to electrical insulation, such as:
- High dielectric strength and non-conductive
- Heat resistance and flame retardancy
- Can be formulated with UV stability
- Dimensional stability with low water absorption
ABS
Also known as acrylonitrile butadiene styrene, ABS plastic is a durable, strong material with toughness, impact resistance, and rigidity. ABS plastic is slightly less heat-resistant than other electrically insulating materials, with a functional operating range of up to 76°F. This material still offers a suitable option for electrical enclosures, housings, and components, offering good electrical insulation with properties that include:
- Non-conductive
- Withstands physical stress
- Easily molded or machined
- Prevents electrical leakage
PTFE
PTFE, or Teflon®, is a synthetic fluoropolymer, demonstrating chemical inertness and weather and UV resistance. While it has limitations—such as low tensile strength, high wear, and an inability to be melt-processed—PTFE offers a range of electrical insulation properties, making it an excellent choice for electronic applications, including protective tubing and cable insulation. Maintaining its electrical properties even in wet conditions, PTFE is favorable due to its:
- High dielectric strength with low electrical loss
- Arc resistance and high surface resistivity
- Resistance to moisture and chemical exposure
- High-temperature stability and non-flammability
G10/FR-4
Made from layers of glass cloth soaked in epoxy resin, G10/FR-4 materials offer a high strength-to-weight ratio, thermal stability, and machinability. It is a strong, durable option that can withstand significant stress and temperature changes without deforming and provides excellent electrical insulation. G10/FR-4 is an ideal option for terminal boards and printed circuit boards, as well as other electrical applications, offering material characteristics such as:
- High dielectric strength
- Low moisture absorption
- High mechanical strength
- Chemical and thermal resistance
