Electrical Insulation Coatings

In modern electronics manufacturing, reliable and efficient insulation solutions are indispensable. They protect electronic components from unwanted electrical contact, harmful environmental influences, and premature aging. Plasma-polymer thin-film systems are PFAS- and halogene-free and offer optimized solutions in this context. These technological innovations combine advanced material properties with a sustainable manufacturing process, providing an attractive alternative to conventional insulation methods such as potting compounds and lacquer systems. At Fraunhofer IFAM, plasma technology is used to produce ultra-thin, partial-discharge-resistant layers in the micro- and sub-micrometer range, significantly enhancing the performance and longevity of electronic components.

Advantages of Plasma Technology for Insulation Coatings

The production of electrical insulation coatings using plasma technology offers numerous benefits, making it an ideal solution for modern manufacturing processes:

• Environmentally Friendly Process: The process requires no solvent additives, produces no volatile organic compounds (VOCs), and is halogen- as well as PFAS-free. This not only reduces emissions but also minimizes the need for extensive occupational safety measures and simplifies recycling processes at the end of a product’s life.
• High Aging Stability: Plasma-polymer coatings provide increased resistance to environmental influences, extending the lifespan of electronic components.
• Efficient and Cost-Saving Production: With no drying processes required, the procedures are time-efficient and economically viable.
• Optimized Resource Utilization: Coatings can be applied locally and as needed, supporting resource-efficient processing.
• Automatability: The processes can be seamlessly integrated into automated production lines, enabling precise process monitoring.
• Thermal Management: The minimal coating thickness (< 2-5 µm) contributes to improved heat dissipation of components.
• Repair-Friendly: The ability to selectively remove coatings simplifies maintenance and repair processes.

Flexible Process Solutions

The application of coatings can be carried out as required, either inline using robotic or motion systems at atmospheric pressure (AP) or in a low-pressure (LP) plasma process. This offers high flexibility for processing complex three-dimensional geometries.

Application Examples

Plasma-polymer insulation coatings are used in various technological areas, including:

• Protective Layers on Metal Powders: Ensure insulating properties and prevent unwanted electrical contact.
• Insulating Coatings for Conductor Tracks: Enhance operational safety and protection against external influences.
• Replacement for Insulating Lacquers: On electronic boards and coils, this coating solution may replace conventional insulating lacquers, enabling a more efficient and environmentally friendly production process.

The PFAS-free potential of plasma-polymer protective coatings offers a wide range of applications as (complementary) insulation systems. The typically used thin coating thicknesses, below 2 micrometers, are easily incorporated into applications since they fall below typical manufacturing tolerances or can be easily added. The design flexibility for various applications on diverse geometries completes the requirement profile.