Insulation Technology Glossary
114 technical terms from the world of electrical insulation materials, processing methods and standards.
Aramid Paper
High-performance insulating material made from aramid fibres for electrical and high-voltage technology, with excellent thermal and mechanical resistance.
Armature Insulation
Insulating parts in electrical machines that reliably separate winding wire, iron core and commutator from each other.
Battery Insulation
Insulation system for protecting battery cells and modules from short circuits, overheating and mechanical damage.
Bent Parts
Components manufactured by precision bending processes from materials such as metal, films and laminates.
Breakdown Voltage
Electrical voltage at which an insulating material loses its insulation capability and an uncontrolled current begins to flow.
Bridge Die Cutter
Specialised die-cutting machine with a movable bridge for the precise manufacture of formed parts from insulating materials.
Cable Insulation
Covering of electrical conductors with insulating materials for protection against short circuits, electric shocks and environmental influences.
Capacitor Insulation
Dielectric between capacitor plates that prevents direct current flow and stores electrical energy in the field.
Commissioning Warehouse
Warehousing method in which the supplier stocks goods at the customer until sale or consumption and only invoices upon withdrawal.
Composite Materials
Materials made from two or more components that achieve properties through combination which none of the individual materials offers alone.
Consignment Warehouse
Inventory method in which the supplier remains the owner of the goods until the customer consumes or sells them.
Contract Slitting
Service in which a specialised converter cuts roll material to exact widths and lengths on behalf of the customer.
Converting Processes
Further processing of web-form materials through cutting, stamping, laminating and forming into ready-to-use products.
Copper Foil
Thin metallic material with high electrical and thermal conductivity, used in EMC shielding and printed circuit board manufacturing.
Copper vs Aluminium Windings
Comparison of the two winding materials for transformers and motors in terms of conductivity, weight, cost and efficiency.
Corona Discharge
Electrical discharge at points of high field strength that generates ozone and damages insulating materials over the long term.
Creepage Distance
Shortest path along the surface of an insulating material between two conductive parts, important for dimensioning the insulation.
Cross-section Reduction
Reduction of the conductor cross-section, which increases electrical resistance and can lead to unwanted heating.
Deflection Curves
Description of the deflection of a component under load, relevant for calculating the load-bearing capacity of insulating parts.
Dielectric Losses
Energy loss in an insulating material caused by molecular polarisation in an alternating electric field, manifesting as heat.
Dielectric Strength and Breakdown Voltage
Maximum electric field strength that an insulating material can withstand before dielectric breakdown occurs.
Dielectric Withstand Strength
Ability of an insulating material to withstand an applied electrical voltage without breakdown.
DIN 8580 (Manufacturing Processes)
Fundamental standard classifying manufacturing processes into six main groups: primary shaping, forming, separating, joining, coating, and changing material pro...
DIN ISO 2768
Standard for general tolerances for linear and angular dimensions as well as form and position without individual tolerance indication.
DMD Laminate
Three-layer insulating material made from polyester nonwoven, polyester film and nonwoven with high dielectric strength for motors and transformers.
Electric Field Strength
Physical quantity describing the force on an electric charge within an electric field, measured in V/m.
Electric Motor Winding
The functional heart of an electric motor: current-carrying conductors with a matched insulation system of slot insulation, layer insulation and turn insulation...
Electrical Conductivity
Physical material property indicating how well a material conducts electric current, measured in Siemens per metre.
Electrical Dielectric Strength
Maximum electric field strength in kV/mm that an insulating material can withstand without breakdown, measured according to IEC 60243.
Electrical Insulating Films
Thin, flexible films with high dielectric strength, used as electrical insulation in motors, transformers and electronics.
Electrical Insulators
Components made from non-conductive materials that separate live conductors from earthed structures and ensure electrical safety.
Electrical Transformer
Electrical machine for transforming alternating voltages, operating on the principle of electromagnetic induction.
Electrically Insulating Coatings
Applied layers that reliably prevent the flow of electrical energy between components.
Electrically Insulating Plastics
Plastics with high specific resistance, used as insulating materials in electrical engineering.
EMC Shielding
Measures to reduce electromagnetic interference between electrical and electronic systems by means of shielding materials.
Field Coil Insulation
Multilayer insulation for field coils in DC machines and generators, separating the winding from the pole core and housing.
Film Extrusion
Continuous manufacturing process for producing plastic films by melting and forming polymer granulate.
Filter Nonwoven
Porous sheet filter medium for separating particles from gases or liquids, made from synthetic or natural fibres.
Foam Tape
Self-adhesive construction element based on foamed polymers for sealing, damping and insulation in industrial applications.
Form Coils
Prefabricated, precisely shaped windings for electrical machines with high precision and reproducible quality.
Forming Technology
Manufacturing process in which materials are deliberately brought into the desired shape through plastic deformation.
Hairpin Stator
Stator technology with U-shaped copper conductors (hairpins) for electric motors with higher fill factor and better heat dissipation.
Hairpin Winding
Winding technology with U-shaped pre-bent copper conductors for electric motors with high fill factor and compact design.
High-temperature Insulation
Insulating materials such as ceramic fibres, silicate boards and mica for extreme thermal protection in industrial high-temperature processes.
High-voltage Insulation
Insulation system for electric motor windings with specific requirements for efficiency, dielectric withstand strength and long-term stability.
High-voltage Insulation
Insulation systems for electrical installations with voltages above 1 kV, placing increased demands on dielectric strength and tracking resistance.
HOSTAPHAN Polyester Films
Polyester films from Mitsubishi with temperature resistance from -70 °C to 150 °C, used in electrical engineering and packaging.
Hydraulic Lifting Device
Systems for precise and safe handling of heavy loads using pressurised fluid in industrial manufacturing.
Insulating Film Cutting
Precision cutting of electrical insulating films into defined geometries for motor and industrial applications.
Insulating Material
Materials with high electrical resistance that reliably prevent current flow between conductive parts.
Insulation Paper (Electric Motors)
Specialty papers made from cellulose or aramid fibres, used as electrical insulation between windings and iron core in electric motors.
Insulation Properties
The full set of material properties that determine a material's ability to prevent the flow of electrical energy or heat.
Insulation Resin
Liquid or pasty material for the electrical, mechanical and thermal protection of windings and assemblies in electrical engineering.
Insulation Resistance
Electrical resistance of an insulating material, indicating how well it prevents current flow between conductors, measured in megohms.
ISO 9001
International standard for quality management systems, defining requirements for processes, documentation and continuous improvement.
Kanban Stock
Inventory-controlled storage system based on the pull principle, in which consumption automatically triggers replenishment.
Kapton Adhesive Tape
Polyimide film from DuPont with extreme temperature resistance up to 400 °C, used in aerospace and high-performance electronics.
Kiss-Cut
Partial stamping process in which only the face material is cut through without damaging the underlying carrier liner.
Knife Shaft
Rotating shaft with rotating cutting blades for precise longitudinal slitting of films, papers and nonwovens.
Laminate Composites
Multilayer materials made from films, papers and resin systems, joined by lamination or bonding into high-performance insulating materials.
Laminated Film
Composite film in which several material layers are bonded into a laminate through lamination.
Layer Insulation
Insulating layer between winding layers in electric motors and transformers that prevents voltage flashover between layers.
Material Thickness
Distance between the two surfaces of a material, determining stability, flexibility and electrical insulation capability.
Matrix Stripping
Process step after die cutting in which the waste matrix is stripped from the web to expose the finished parts.
Mica Composite (Mikanit)
Composite material made from mica flakes and a binder with outstanding electrical insulation capability and heat resistance.
Mica Tape
Mica-based insulation tape that withstands temperatures up to 300 °C and serves as fire protection insulation in high-voltage machines.
Minimum Bending Radius
Smallest permissible curvature a material can take when bent without breaking or losing its properties.
Molded Parts
Insulating parts with defined geometry, produced by stamping, bending or forming, for installation in electrical machines.
Multilayer Insulation Materials
Insulating materials made from several stacked insulating layers for increased dielectric withstand strength and mechanical load capacity.
Mylar
Brand name for biaxially oriented polyester film (BoPET) with high dielectric strength and low moisture absorption.
Partial Discharge
Localised electrical discharge within an insulation system without full breakdown, causing gradual ageing of the insulating material.
Partial Stamping
Chipless cutting process using punch and die, in which films and insulating materials are only partially stamped through.
Polyester Film
Versatile thermoplastic insulating material (PET) with high mechanical strength, dielectric strength and temperature resistance up to 150 °C.
Polyethylene (PE)
Most produced plastic in the world with good electrical insulation properties, available as HDPE, LDPE and LLDPE.
Polyimide (PI)
High-performance polymer with extreme temperature resistance up to 400 °C, the basis for Kapton and other specialty films.
Polypropylene Films
Thermoplastic films made from polypropylene (PP) with good chemical resistance, low density and versatile usability.
Polystyrene Film
Transparent, formable plastic film based on polystyrene, used in packaging, electronics and as insulating material.
Pressboard
Technical material made from compressed cellulose fibres with good electrical insulation properties and high mechanical strength.
PV Backsheet
Rear protective and insulating layer of photovoltaic modules, providing weather protection and electrical insulation.
R-PET and A-PET
Two variants of polyethylene terephthalate: R-PET made from recycled material and A-PET as an amorphous variant with high transparency and formability.
Recycled Content
Percentage share of recycled material in a product, an important indicator for sustainability and resource efficiency.
Rewind Slitting
Manufacturing process for splitting wide material rolls into narrower rolls with precise longitudinal or cross cuts.
Roll Slitting
Precision process for longitudinally dividing web-form materials such as films, paper or fabric into defined widths.
Rotary Die Cutting
High-productivity stamping process with rotating cylinders that continuously produces formed parts from roll material.
Sealing Technology
Controlling the leakage or ingress of liquids, gases or solids at connection points using suitable sealing materials.
Separator Films
Functional separating film for isolating components, layers or media in batteries and industrial processes.
Sheet Insulation Materials
Large-area, flexible insulating materials in film, paper or nonwoven form for electrical insulation in the electrical industry.
Slot Closure Wedges
Wedge-shaped insulating parts inserted into the open side of the stator slot to mechanically fix the winding.
Slot Insulation
Insulation of stator slots in electric motors and generators: protects windings from mechanical damage and electrical breakdown.
Slot Liner Covers
Insulating cover elements in electric motors that protect and fix winding heads in the slot area.
Stamped Parts
Components produced by precision stamping processes from films, papers and insulating laminates for industrial applications.
Surface Leakage Current
Unwanted current flow across the surface of an insulating material, caused by contamination, moisture or ageing.
Surface Protection Film
Temporary protective solution for sensitive component surfaces during manufacturing, transport and assembly.
Surface Resistance
Electrical resistance that an insulating material presents to current flow along its surface.
Tensile Strength
Maximum mechanical stress a material can withstand under tensile load before breaking, measured in MPa or N/mm².
Thermal Classes of Insulation
Classification of electrical insulating materials by their maximum continuous operating temperature according to IEC 60085 into classes Y, A, E, B, F, H and C.
Thermal Conductivity
Material property indicating how well a material conducts heat, measured in W/(m·K).
Thermal Insulation
Materials and systems for reducing heat transfer between areas of different temperature.
Thermoplastics
Plastics that become formable when heated and resolidify upon cooling, widely used as electrical insulating materials.
Thermosets
Plastics with an irreversibly cross-linked molecular structure that cannot be reshaped after curing and offer high temperature resistance.
Through-Cut
Cutting process in which all material layers, including the carrier liner, are completely severed.
Triflexil
Flexible insulating laminate made of Nomex and polyester film in thermal class F (155 °C) for motors and transformers.
Trivoltherm
Flexible sheet insulation material with excellent electrical and thermal insulation properties for demanding applications.
Turn Insulation
First and most important insulation layer in an electric motor: separates individual conductor turns and prevents short circuits between wires.
Viledon Filter Mats
Filter nonwovens by Freudenberg for air and liquid filtration in industry, building services and paint technology.
Voltage Breakdown and Breakdown Voltage
Uncontrolled current flow through an insulating material when the breakdown voltage is exceeded.
Vulcanised Fibre
Sustainable cellulose-based material with high mechanical strength, arc resistance and good insulation properties.
Web Edge Guiding
System for precise guiding of web-form materials during slitting and winding processes to prevent misalignment.
White Goods
Collective term for large household appliances such as washing machines, refrigerators and dishwashers, which require insulating materials in motors and electro...
Winding Shaft
Component for the controlled winding and unwinding of web-form materials in slitting and converting equipment.