High-temperature films replace traditional insulation materials

The demands placed on modern electrical and industrial systems are constantly increasing. Higher power densities, more compact designs, and rising temperatures are pushing traditional insulation materials to their limits. At the same time, the need is growing for materials that combine electrical insulation, thermal stability, and mechanical strength.

Against this background, high-temperature films are becoming increasingly important. In numerous applications, they are replacing traditional insulation materials and enabling new technical solutions in fields such as electromobility, power electronics, aerospace, and industrial automation.

Why classic insulation materials are increasingly being replaced

Traditional insulation materials such as standard polyester films, paper insulation, or simple thermoplastic materials still reliably meet many requirements. However, they are increasingly reaching their technical limits in modern high-performance applications.

Typische Herausforderungen sind:

• increasing operating temperatures
• higher electrical voltages
• more compact designs
• increasing thermal loads
• higher demands on lifespan and reliability

Particularly in areas such as power electronics, electric motors and battery systems, temperatures are generated that can damage conventional materials in the long term.

What are high-temperature films?

High-temperature films are technical films specifically designed for applications with high thermal and electrical loads. They are often based on high-performance polymers with exceptional temperature resistance and stable dielectric properties.

The most important materials include:

• Polyimide (PI)
• Polyetheretherketone (PEEK)
• Polyethylene naphthalate (PEN)
• Polyphenylene sulfide (PPS)
• PTFE and fluoropolymers

These materials allow for continuous operating temperatures significantly higher than those of standard plastics.

Polyimide films as an established high-performance material

One of the most famous High-temperature films is the polyimide film. It is characterized by:

• very high temperature resistance
• excellent electrical insulation
• high radiation resistance
• low outgassing

.

Polyimide films are used particularly where temperatures exceeding 200 °C can occur, for example in:

• Electric motors
• Transformers
• Aerospace Engineering
• power Electronics

For short periods, temperatures up to approximately 400 °C are even possible.

PEEK films for extreme applications

PEEK is one of the highest-performing engineering plastics available. PEEK films offer:

• very high mechanical strength
• excellent chemical resistance
• high continuous operating temperatures
• excellent dimensional stability

This makes them suitable for applications with extreme requirements in:

• Aviation
• Medical Technology
• High-performance electronics
• industrial high-temperature areas

PEN and PPS as modern alternatives

Materials such as PEN and PPS are also becoming increasingly important.

PEN films

Compared to classic polyester films, PEN films offer:

• higher temperature resistance
• improved hydrolysis resistance
• higher dimensional stability

They are frequently found in:

• Transformers
• flexible printed circuit boards
• electrical insulation systems

employed.

PPS foils

PPS is characterized by:

• high chemical resistance
• low water absorption
• good electrical properties
• high temperature stability

It is particularly suitable for demanding industrial applications.

Market trend: Miniaturization and higher power densities

A key driver for the use of high-temperature films is the increasing miniaturization of electronic systems.

Modern applications require:

• more compact designs
• higher power densities
• thinner materials
• higher thermal resistance

This makes high-performance films a central component of modern designs.

Significance for electromobility and power electronics

The use of high-temperature films is growing particularly strongly in:

• Electromobility
• Battery systems
• inverters
• charging infrastructure
• power Electronics

This creates high temperatures and electrical loads that are difficult to control with conventional insulation materials.

High-temperature films enable:

• higher reliability
• longer lifetime
• improved electrical safety
• more compact designs

Replacing traditional materials with high-performance films

In many applications, high-temperature films are now replacing:

• classic paper insulation
• Standard polyester films
• conventional thermoplastics

The reasons for this are:

• improved temperature resistance
• higher electrical resistance
• reduced aging
• higher chemical stability

This allows for the creation of more powerful and longer-lasting systems.

Requirements for modern high-temperature films

The demands placed on high-temperature films are constantly increasing.

When evaluating solutions, organisations should ensure that the system provides:

• high continuous operating temperature
• low water absorption
• stable electrical properties
• flame retardancy
• mechanical resilience
• Chemical resistance

Additionally, topics such as: are gaining traction.

• weight loss
• Sustainability
• workability
• UL approvals

in importance.

High-temperature films at Dr. Dietrich Müller GmbH

Dr. Dietrich Müller GmbH offers a broad portfolio of high-performance technical films for demanding applications in industry and electrical engineering.

The portfolio includes, among other things:

• polyimide films
• PEN films
• PEEK films
• polyester films
• PTFE films

The materials are used for applications in:

• Electric motors
• Transformers
• power Electronics
• Battery systems
• industrial insulation systems

employed.

In addition to supplying materials, Dr. Dietrich Müller GmbH also provides support with:

• material selection
• application
• Order picking (inter alia also bulk goods for diverse destinations)
• customized solutions

Summary: Key takeaways about intuitive eating

The market trend clearly shows that high-temperature films are increasingly replacing classic insulation materials.

Increasing demands in electromobility, electronics, and industry make high-performance insulation solutions indispensable. Modern high-performance films enable higher temperatures, more compact designs, and improved electrical safety.

With their combination of thermal stability, electrical insulation and mechanical strength, high-temperature films are among the key materials for modern high-performance applications.

Neben klassischen Polyimidfolien gewinnen auch Hochleistungskunststoffe wie Peek, PEN and PPS zunehmend an Bedeutung. Diese Materialien eignen sich hervorragend für Anwendungen in der Elektromobilität, Leistungselektronik und elektrischen Isolation, bei denen hohe thermische und mechanische Anforderungen erfüllt werden müssen.