Converting processes refer to the totality of all procedures used to cut, coat, laminate or further process web-shaped or flexible materials such as films, papers, nonwovens, laminates or insulating materials. The term derives from the English verb “to convert”. In practice, the goal is to transform semi-finished products into ready-to-use products or customer-specific blanks through various processing steps.
Converting processes play a central role especially in the electrical industry and the automotive sector. There, insulating materials such as polyester films, aramid paper or GFRP laminates must be cut, stamped or laminated exactly to ensure reliable function and high operational safety.
Technical details and process steps
Converting processes comprise numerous machining techniques that differ depending on material and application:
- Cutting and roll slitting: web goods such as insulating films or pressboard are brought to customer-specific widths and lengths.
- Stamping and laser processing: production of complex geometries for insulating parts, gaskets or spacer plates.
- Lamination: multilayer materials such as NMN laminates (Nomex-Mylar- Nomex) or DMD (Dacron-Mylar-Dacron) are created.
- Coating and impregnation: improvement of surface properties, for example through resin application for higher temperature or chemical resistance.
- Embossing and scoring: mechanical preparation to improve processability or adaptation to installation spaces.
These processes make it possible to adapt materials precisely to the requirements of electric motors, transformers or automotive components.
Advantages of Converting Processes
Converting technologies offer a number of advantages:
- Precision: high dimensional accuracy in blanks, even with thin or sensitive materials.
- Flexibility: broad material spectrum, from paper through films to multilayer insulating materials.
- Efficiency: automated processes enable economical production even in large quantities.
- Material optimisation: combination of several layers into functional laminates with improved properties.
- Sustainability: waste reduction and resource-conserving processes when properly designed.
Typical Applications
In the electrical industry, converting processes are essential for:
- Slot insulation in electric motors
- Interlayers in transformers
- High-temperature insulation laminates
- Films for cable insulation and sensor technology
In the automotive industry they are used for:
- Insulating parts for battery modules and power electronics
- Gaskets and spacers made of HPL or POM
- Acoustic and thermal protection films
- Lightweight components made of laminated composite materials
Materials and Substances
The following materials are particularly often processed in the converting sector:
- Insulating films: polyester (PET, Hostaphan), polyimide (Kapton), polyethylene (PE)
- Insulating papers: pressboard, aramid paper (Nomex), vulcanised fibre
- Laminates: NMN, DMD, FR4, GFRP profiles
- Plastics: PTFE, POM, UHMW-PE for sliding and wear parts
- Thermosets and resins: for temperature- and chemical-resistant applications
The choice depends on temperature resistance, mechanical load, electrical insulation and cost.
Challenges and Quality Aspects
Converting processes require a high degree of process control. Typical challenges are:
- Dimensional accuracy in thin films and nonwovens
- Avoidance of burrs, cracks or material misalignment
- Ensuring consistent laminate quality
- Compliance with standards such as ISO 9001 or DIN ISO 2768 for tolerances
- Consideration of thermal expansion and surface leakage currents in the end application
GOBA Takeaway
Converting processes are the backbone of modern manufacturing processes in the electrical and automotive industries. They enable the precise processing of complex materials into application-ready insulating parts, laminates and speciality films. Decisive factors are clean process control, the right material selection and compliance with relevant standards. Those who take these factors into account benefit from long-lasting, safe and economical solutions for demanding applications.
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