The Power of Polyimide Tape: Kapton® Tape's Versatile Alternative

Polyimide tape is the preeminent tape product for applications that demand the highest level of performance. Its conformability, damage resistance, and thermoset adhesion properties allow it to withstand exceptionally tough conditions, day in and day out. These Kapton® tape alternatives feature the same exceptional product qualities while costing you substantially less.

Read on to learn about all the benefits polyimide tape has to offer.

What Is Polyimide Tape?

Polyimides are a category of polymers, first identified in 1908. The polyimide Kapton was pioneered in the 1960s. Today, it is highly prized across countless industries including electronics manufacturing, aerospace engineering, and 3D printing. Its high molecular weight makes it a remarkably sturdy insulator, even when used in ultra-thin tape form.

To turn polyimide into an adhesive tape, the polyimide resin is first heated and spread into a film. Once dried, that film is coated with a high-performance silicone adhesive. The adhesive is formulated to remain flexible and stable across a wide range of temperature and environmental conditions. The adhesive is also designed to thermoset, increasing adhesion value and resisting re-softening. The film is then slit into the desired tape width and rolled onto a plastic core, ready to use.

Key Features and Advantages of Polyimide Tape

While different industries value polyimide tape for different reasons, there are two key features that it tends to be universally celebrated for: its temperature and environmental resistance and its electrical isolation properties.

Temperature and Environmental Resistance

Polyimide tape resists temperatures as low as -269°C (-452°F) and as high as 260°C (500°F). This means that even at extreme temperatures, it remains stable and resists tearing and abrasions. It is also excellent at resisting acids, oils, solvents, aging, staining, and water immersion. It is even well suited to protecting gold contacts from molten solder during the hot air solder leveling process.

Naturally, these resistances make polyimide tape a durable, reliable material under tough conditions. But the benefits don’t stop there. Even after the tough conditions have passed, the tape’s properties also help make it easier to peel off, and its stability means it leaves minimal residue behind for easier cleanup.

Electrical Isolation Properties

Polyimide tape meets the UL510 standard for insulating tape. It has a dielectric strength greater than 4000 V at a 1 mil thickness, and greater than 8000 V at 2 mil thickness. This strength makes it a suitable insulation layer for all manner of electrostatic-sensitive components where preventing electrical leakage and environmental infiltration is critical.

Applications and Industries for Polyimide Tape

The potential applications for polyimide tape are innumerable. To give a snapshot of its current use cases, three of these industries are examined below: electronics manufacturing, 3D printing, and aerospace engineering.

The Role of Polyimide Tape in Electronics Manufacturing

Electronics manufacturers and repair professionals frequently use polyimide tape to wrap sensitive components, such as coils, sensors, capacitors, switches, transformers, and magnetic wires. The most valuable properties cited by professionals in this industry include:

• Flexibility
• Adhesion strength
• Heat resistance
• Electrical isolation
• Optical clarity

Thanks to these properties, even complex or delicate components can be covered easily. The resulting barrier is strong enough to withstand a wide range of harsh environmental conditions and allows visual monitoring of the wrapped component if necessary. Finally, when the tape needs to be removed, it comes away cleanly, without compromising the components it was applied to.

The Role of Polyimide Tape in 3D Printing

For casual and professional 3D ABS printers alike, polyimide tape has emerged as an indispensable tool for clean, consistent print release. The heat resistance and stability of the film allow it to fully protect heated glass printing beds while preventing warping during the print cooling process.

The Role of Polyimide Tape in Aerospace Engineering

Very few materials can keep up with the levels of environmental strain aircraft and spacecraft experience. Polyimide tape is one of them. The New Horizons spacecraft, for example, used polyimide to maintain an operating temperature between 10° C and 30° C for its entire nine-year journey to Pluto. Both civil and military aircraft also use polyimide tape to wrap electrical wiring, where its light weight is particularly valued.

Choosing the Right Tape for Your Needs

There are twelve widths of polyimide tape available at Tape Jungle, ranging from ¼” (6.3mm) to 4”(101.6mm). Choosing the right width is a simple matter of knowing your coverage needs. Of course, larger widths can be cut down to smaller applications, but to save both time and effort it’s ideal to have the correct width to work with from the start.

As for thickness, there are thinner 1 mil and thicker 2 mil options available for each width. The key to choosing the right polyimide tape thickness is balancing flexibility and weight against overall protection and durability.

Higher wear and tear applications are more likely to need the thicker 2 mil tape. This additional thickness allows for greater tensile strength, dielectric strength, and elongation. Conversely, small and delicate work is often best handled with the thinner 1 mil tape, which provides maximum flexibility.

How to Use Polyimide Tape Effectively

Using polyimide tape effectively requires consideration of both its application and its storage.

First, to ensure the best adhesion possible, surfaces should be cleaned of grease, oils, and other contaminants before polyimide tape is applied. Unroll the tape directly onto the application surface to minimize unnecessary contact with the adhesive. You do not need to apply excessive pressure to create a secure bond.

As for storage, polyimide tape’s stability and durability mean it does not require any special conditions. Simply keep it in its original packaging at room temperature and use it within 24 months from the date of manufacture.

Preserve Performance While Saving with Polyimide Tape

All the exceptional qualities that have made Kapton® tape a mainstay for over 50 years can be had for less when you choose a high-performance Kapton® tape alternative. The polyimide tape available at Tape Jungle is electrical grade, silicone adhesive coated, and residue-free. Find the right roll for your needs when you explore your options at Tape Jungle today.