Material Spotlight: Nomex

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A suitable electrical insulator can help prevent electric shocks and other electricity-related hazards. But how would you know which products are the best and most reliable? Don’t fret! ESPE Manufacturing Co., Inc. got you covered! We have one of the most extensive inventories of electrical insulation in the Midwest.

In this article, we feature our Nomex product lines, one of the high-quality products we designed, manufactured, and distributed. We vigorously promote our customized Nomex products to meet the wide range of applications requiring excellent compact insulation materials.

So, What Is Nomex?

Nomex is a flame-resistant material developed by DuPont in the early 1960s and was first commercialized in 1967. It is typically available in two forms: paper, or rolls of thin gauge material, and pressboard, or sheets of medium or thick gauge material. What’s more, Nomex is chemical, thermal, and radiation resistant, allowing it to strengthen and extend the life of your products.

When it comes to electrical insulation, it has long gained recognition for exceptional quality and dependability. Use it appropriately, and it will extend the useful life of your electrical system while decreasing the likelihood of it malfunctioning.

What Are Electrical Insulators, And Why Are They Important?

Electrical insulators, as the name implies, are synthetic materials that resist the current that flows through them. Simply put, electricity does not pass through these materials because the primary function of insulators is to prevent electricity from flowing outside of conductors and contain it only where it is supposed to flow.

These materials are essential in preventing electrical hazards such as electricity leakage and electric shock. Short circuits with low current flows, which are frequently caused by poor electrical insulation, are often the source of leaks. On the other hand, electric shocks occur when a person comes into contact with a source of electric energy. Take note that the results of these shocks can range from no injury to death.

To better understand how electrical insulators work, examine how electrical cables are made and structured. These cables are typically filled with wires made of metals such as copper, aluminum, and silver. The wires serve as electrical conductors, allowing electricity to flow freely. After securing the inside of the cables, coatings are added to act as insulators, and they only allow electricity to flow within the cord. Nylon, PVC (Polyvinyl Chloride), and wire enamels are some commonly used standard coatings.

One of the most crucial things to remember is that electrical insulators are critical and must be used correctly. Each has resistance value, so choosing the best material for your application is vital.

What Is Nomex Insulation Paper, And Other Nomex Types?

Nomex 410 is the original Nomex insulation paper widely used in various electrical equipment applications, including sheet insulation and manufacturing of electrical components. It possesses high-performance insulation with excellent intrinsic material capacity, electrical durability, flexibility, and resilience. It is sold in rolls with thicknesses ranging from 0.002-0.03 in (0.05-0.76 mm) to accommodate a wide range of gravities.

Some of the features of Nomex 410 include:

• Excellent heat-resistance ability and does not melt easily
• Quality thermal stability that can withstand temperatures up to 220°C
• Satisfactory resistance to splitting and scraping
• Intrinsic dielectric strength
• Broad chemical compatibility that can resist solvents, acids, and alkalis

Additionally, some of the applications of Nomex 410 are:

• Wire and cable industry
• Welding equipment
• Mining equipment
• Engine and motors industry
• Electrical and electronic industry

We also offer other available Nomex products which cover every type of Nomex paper and pressboard and serve your custom-manufactured fabricated parts:

Nomex 993 is a sheet pressboard material available in thicknesses ranging from 0.04-0.16 in (1.0-4.0 mm) for specific gravities. This product can preserve its general structure and resistance while conforming to minor imperfections on the exterior it is lining. Nomex 993 also seals well with electrical contacts.

Nomex 994 is the denser version of Nomex 993. It is typically used in similar but more heavyweight applications. It is available in thicknesses of 0.04-0.380 in (1.0-9.6 mm) and can withstand compressive loads due to its superior stability and excellent absorption.

Let ESPE Handle All Your Nomex Needs!

ESPE Manufacturing Co., Inc. is ready to help you find the best insulation solution for your electrical systems. With a complete stock of Nomex 410, Nomex 993, and Nomex 994 product lines available, combined with our full suite of fabrication and manufacturing capabilities, we ensure to be your go-to source for Nomex rolls, sheets, and other products.

We can help you develop and manufacture prototypes and customized parts in low or mass-producing orders at the quickest turnaround time possible. React to us and request a quote for your next project.

Formex for Insulation of Batteries & Printed Circuit Boards (PCBs)

Electrical insulation involves non-electrically conductive material used to control the flow of electricity and protect sensitive components. Various materials can be used, such as rubber, plastic or material like Formex for insulation. These materials work by blocking the passage of electrons more effectively than semiconducting and conducting materials. This means that they can be used as a protective barrier around the conductor, ensuring energy stays on a specific path and doesn’t interact with other components, causing short-circuiting.

Importance of PCB & Battery Insulation

In applications involving PCBs, insulation acts as the dielectric material used to separate conducting elements and layers. Most PCBs used today are multilayered, which means multiple adhesion points are present. This increased board height requires more soldering and makes proper insulation vital to the board’s effectiveness. In PCB applications, having a thorough understanding of your PCB’s construction is the best way to ensure it’s insulated adequately and can operate at its highest potential.

Another key application for electrical insulation is in batteries. Electrical vehicle batteries, for example, require insulation between each component to ensure no electrical arc can arise between battery components. This is a necessary precaution to prevent fires, shocks, high temperatures, short circuits, and more.

When choosing a material to insulate PCBs and batteries, there are several factors that should be considered. One of the primary concerns is the material’s thickness in relation to its efficiency. Insulating material needs to be highly effective, but thickness also needs to be taken into account. Certain insulation applications feature highly compact components that are not suited to a particularly thick material.

It’s also important to consider what type of processing your insulator should undergo. Certain insulation materials are significantly easier to process than others and, depending on your application, this may be a significant concern. However, an easy-to-process material might not perform according to your required standards. Insulation weight and cost-to-function ratio should also be factored into decision-making. For PCB and battery insulation applications, a particularly high-performing material is ITW Formex. This material is uniquely suited to PCB and battery applications, meeting all of the typical demands.

Why Formex?

ITW Formex is ideal for protecting delicate components and is widely used throughout many applications. It offers excellent dielectric strength and provides reliable mechanical protection. Formex can be formed into even the most complex three-dimensional shapes by die-cutting, scoring, and bending. In PCB insulation applications, Formex is used for barriers between PC boards as well as between PC boards and housings.

Formex electrical insulation is made from polypropylene, which is lightweight and inexpensive, while meeting rigorous electrical barrier and insulation requirements. With a flame class rating of UL 94V-0, Formex has excellent flame-retardant properties and will not combust or melt at temperatures up to 239° F.

Additionally, ITW Formex features several key characteristics that allow it to outperform other insulation materials, such as preventing electrically charged components from arcing. Formex is ideal for many types of EV battery applications as it protects from contact corrosion, provides EMI shielding capabilities, and more. For electric vehicle battery applications, Formex stands up to chemical, mechanical, and environmental demands.

ESPE Manufacturing: Your Source for Reliable Insulation

PCBs and batteries are used throughout nearly every industry and require high performing, reliable insulation. Formex contains many beneficial characteristics that make it ideally suited to these applications. In addition to being uniquely easy to shape, it also features notable strength and valuable fire-retardant properties, all while being cost-effective.

ESPE Manufacturing Co., Inc., has been providing high-quality electrical insulation solutions since 1948 and features one of the largest inventories in the Midwest. We offer ITW Formex rolls and sheets and carry several varieties suitable for a wide selection of applications. Our experts can help you select the best type for your project. Browse our catalog or contact us to get started. To partner with us and take advantage of Formex insulation for your application, request a quote today.