Mylar Electrical Insulation Tape
 | Mylar Electrical Insulation Tape
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Insulative Tape Company is a manufacturer of mylar electrical insulation tape for transformer interlayer wrapping, motor coil covering, wire harness fixing, battery pack edge protection, and PCB/FPC border isolation. Made with PET polyester film backing and acrylic pressure-sensitive adhesive, the tape is used where thin insulation must hold up under voltage, heat, and tight assembly space. Typical factory checks include 3.5KV-5.5KV breakdown voltage, 1 x 10^12 ohm insulation resistance reference, 130C x 72h heat aging observation, residue review, edge lifting check, and slitting burr control.
Product Photos
Benefits
- Supports electrical separation with typical breakdown voltage around 3.5KV-5.5KV, depending on tape construction and test method.
- PET polyester insulation tape keeps a thin profile while offering stable tensile strength and low stretch for controlled wrapping.
- Typical insulation resistance can reach 1 x 10^12 ohm reference level under controlled sample testing.
- Acrylic adhesive provides balanced adhesion, aging resistance, and clean application on copper, PET, FPC, and coated electrical surfaces.
- Class B 130C can be used as a common thermal reference when the complete insulation system is confirmed.
- Batch sample checks can include 130C x 72h heat aging observation for residue, edge lifting, shrinkage, and flagging.
- Custom slit widths help match transformer layers, motor winding windows, harness branches, battery cell edges, and PCB borders.
- Clean slit edge control helps reduce burrs, film nicks, roll edge powder, uneven winding, and small overlap gaps.
Applications
- Transformer interlayer separation between winding layers and overlap areas
- Transformer coil winding for layer holding and terminal protection
- Motor coil wrapping for stator coils, lead wire fixing, and local protection
- Wire harness covering where thin film strength and color identification are required
- Battery pack edge covering for cell borders, module spacing, and tab area protection
- PCB border isolation for electronic assemblies with limited clearance
- FPC edge protection where thin, stable, narrow-width tape is required
- Capacitor wrapping and electrical component protection during assembly
How Does Slitting Edge Quality Affect Electrical Insulation Stability?
For motor coil wrapping, transformer interlayer separation, battery pack edge covering, and PCB/FPC border isolation, the tape edge is more than a cosmetic detail. A narrow roll with burrs, film nicks, edge waves, or uneven winding tension may lift during wrapping or leave small gaps at the overlap. These small defects can become more serious near sharp copper edges, battery tabs, and flexible circuit borders. During sample confirmation, the slit roll should be checked for clean edges, stable roll density, smooth unwinding, and no obvious edge powder or film tearing.
Technical Data Sheet
Item | Typical Value |
Product Type | PET polyester film electrical insulation tape |
Backing Material | PET polyester film backing |
Adhesive System | Acrylic pressure-sensitive adhesive, silicone adhesive available after confirmation |
Total Thickness | 0.055mm / 0.06mm / 0.08mm typical factory range |
PET Film Thickness | 0.025mm / 0.036mm / 0.05mm reference options |
Adhesive Layer | 0.025mm-0.035mm typical reference, based on confirmed construction |
Color Options | Yellow, amber, clear, blue, red, green, black, white |
Breakdown Voltage | 3.5KV-5.5KV typical reference, depending on film thickness and test method |
Dielectric Strength | 150-200 kV/mm PET film reference range |
Insulation Resistance | 1 x 10^12 ohm typical reference value |
Thermal Class Reference | Class B 130C common reference, final use depends on insulation system |
Short-Term Heat Check | 150C sample exposure possible by construction |
Heat Aging Observation | 130C x 72h sample check for residue, edge lifting, shrinkage, and flagging |
Peel Adhesion | 6-10 N/25mm typical factory test range |
Tensile Strength | >=120 N/25mm typical reference |
Elongation | 40%-70% typical reference |
Slit Width Tolerance | +/-0.2mm common reference, tighter tolerance after sample confirmation |
Slitting Edge Check | Burr control, clean edge, no obvious film nick, edge wave, or roll edge powder |
Supply Format | Jumbo roll, slit roll, sheet, die-cut insulation part |
UL / Flame-Retardant Status | Confirmation available for selected constructions when required |
Product Overview
Mylar electrical insulation tape is a thin polyester film electrical tape used for electrical separation, local covering, and edge protection without adding unnecessary build-up. The PET film gives the tape good dimensional stability and tensile strength, while the adhesive layer helps it stay in place on copper wire, transformer coils, harness branches, battery cell edges, and electronic assemblies.
For this type of tape, thickness alone does not tell the full story. A 0.06mm tape may be built with 0.025mm or 0.036mm PET film, plus different adhesive coating thickness. That difference can affect breakdown voltage, peel adhesion, winding feel, and heat aging behavior. A heavier adhesive layer may improve holding on some surfaces, but it does not automatically improve dielectric performance. For production use, Insulative Tape Company recommends confirming PET film thickness, adhesive layer, slit width, and electrical test data together.
When used as transformer coil winding tape or motor coil insulation tape, the tape should unwind smoothly, hold overlap areas, and avoid flagging after heat exposure. In battery pack insulation tape and PCB/FPC edge insulation, clean slit edges become even more important. Small film nicks, edge waves, or unstable roll tension can leave gaps near copper edges, battery tabs, flexible circuit borders, or compact component corners.
What Should Be Verified Before Using Mylar Tape for High-Voltage Insulation?
Before selecting Mylar tape for transformers, motor coils, wire harnesses, battery modules, or PCB/FPC edge protection, engineering teams should look beyond nominal thickness. Important checks include breakdown voltage, dielectric strength, insulation resistance, adhesive holding after heat aging, overlap coverage, and residue behavior after heating. Breakdown voltage is a laboratory test value, not the safe working voltage of the finished assembly. Final performance also depends on winding tension, tape overlap, surface cleanliness, copper edge radius, operating temperature, and humidity exposure. If UL or flame-retardant confirmation is required, the selected construction should be checked before production use.
FAQ
Is breakdown voltage the same as working voltage?
No. Breakdown voltage is tested under defined laboratory conditions. Long-term working voltage depends on insulation design, overlap, spacing, heat, humidity, and component geometry.
Can this tape be used for transformer interlayer separation?
Yes. It is commonly used for transformer layer separation, coil winding, terminal covering, and overlap holding. Thickness and slit width should be confirmed by sample winding.
What should be checked after heat aging?
Common checks include adhesive residue, edge lifting, flagging, film shrinkage, cracking, and whether the tape still keeps the required electrical performance.
Can the tape be slit into narrow widths?
Yes. Insulative Tape Company can produce slit rolls for coil, battery, harness, PCB, and FPC areas. Burr control, roll tension, and edge cleanliness should be confirmed before production use.