Insulating Films

Thermalfilm™ Polyimide Plastic Films
RoHS Compliant

Thermalfilm™ and Thermalfilm™MT are low cost polymide plastic insulating films designed to be an improved replacement for mica. These insulators have a distinctive amber color and can be easily recognised and assembled on a production line

Thermalfilm™MT, made from high performance Kapton™MT material, provides thermal conductivity nearly 2-5 times greater than standard Thermalfilm™.

Both insulators have an extremely high resistance to flow or thin out under high compressive stresses, particularly at elevated temperatures.

Excellent physical, mechanical and electrical properties remain nearly constant over a wide range of temperatures and frequencies. They are radiation resistant, have no melting points, and have no known organic solvents.

The polymide plastic film is UL listed as a component in UL's publication "Component - Plastic Material" dated September 18, 1969. The UL card number is E39505R, Guide QMFZ2 filed by E.I. du Pont de Nemours & Co., Inc. Thermalfilm is rated 94 V-O.

Notes:
• Thermalfilm™ MT part numbers begin with "46".
• Insulator thickness is .05mm +/- 0.006mm (0.002" +/- 0.00025") unless otherwise specified.
• Dimensional tolerances are +/- 0.38mm(0.015"), hole diameters are +/- 0.25mm (0.010") and angularity is +/- 1 1/2° unless otherwise specified.
For TO-3

Part Number RoHS PCN A B C D
43-03-1G N/A 43.94
(1.730)
31.75
(1.250)
3.56
(0.140)
1.57
(0.062)
43-03-2G 42.04
(1.655)
27.00
(1.063)
3.96
(0.156)
1.57
(0.062)
43-03-3G N/A 42.04
(1.655)
27.00
(1.063)
3.96
(0.156)
4.22
(0.166)
43-03-4G 39.70
(1.563)
26.67
(1.050)
3.56
(0.140)
1.57
(0.062)
43-03-6G N/A 42.04
(1.655)
28.58
(1.125)
3.96
(0.156)
1.57
(0.062)

For TO-5 and TO-18

Part Number RoHS PCN FIG. A B C
43-05-1G
(TO-5)
A 9.91
(0.390)
5.08
(0.200)
0.91
(0.036)
43-05-2G
(TO-5)
B 9.91
(0.390)
5.08
(0.200)
0.91
(0.036)
43-18-1G
(TO-18)
A 6.35
(0.250)
2.54
(0.100)
0.91
(0.036)

Washer

Part Number RoHS PCN Thread A B
43-02-4G #4 6.35
(0.250)
3.05
(0.120)
43-02-10G #10 14.27
(0.562)
5.16
(0.203)
43-02-25G 1/4" 20.62
(0.812)
6.73
(0.265)

For TO-220, TO-126, Case 77, Case 199, Case 90, TO-218, TO-3P

Part Number RoHS PCN A B C D
43-77-1G
(TO-126,case 77)
11.10
(0.437)
7.92
(0.312)
3.56
(0.140)
2.36
(0.093)
43-77-2G
(case 90,case 199)
17.45
(0.687)
14.27
(0.562)
5.54
(0.218)
3.18
(0.125)
43-77-6G
(case 90,case 199)
20.62
(0.812)
14.27
(0.562)
7.14
(0.281)
3.96
(0.156)
43-77-8G
(case 90,case 199)
18.92
(0.745)
13.84
(0.545)
5.38
(0.212)
3.81
(0.150)
43-77-9G
(TO-220)
18.42
(0.725)
13.21
(0.520)
4.32
(0.170)
2.92
(0.115)
43-77-20G
(TO-220,TO-218,TO-3P)
23.24
(0.915)
18.80
(0.740)
6.98
(0.2.75)
3.66
(0.144)

For TO-66

Part Number A B C D Thickness
43-66-2 33.32
(1.312)
19.35
(0.762)
3.56
(0.140)
1.57
(0.062)
0.05
(0.002)

For TO-218

Part Number RoHS PCN Thickness
43-02-95 N/A N/A 0.05
(0.002)

Bulk Thermalfilm™
Part Number RoHS PCN Thickness
4300G 2 MIL 0.051 (0.002)
4500 5 MIL N/A N/A 0.127 (0.005)

Thermalfilm™ / Thermalfilm™MT

Property Electrical -Typical Value @ 25°C Test Method
Thermalfilm™ Thermalfilm™MT
Dielectric Strength 03mm (1 -mil)
275.6 x 103 volts/mm
(7,000 volts/mil)
177.2 x 103 volts/mm
(4500 volts/mm)
ASTM D149-64
Dielectric Constant 3.5 4.3 ASTM D150-64T
Dissipation Factor 0.002 0.002 ASTM D150-64T
Volume Resistivity 1017 ohm-cm 1017 ohm-cm ASTM D257-61
Surface Resistivity 1016 ohms 1016 ohms ASTM D257-61
Corona Start Voltage .025mm (1 -mil) 465 volts 465 volts ASTM D1868-61T
Insulation Resistance 100.00 megohm mfds. 100.00 megohm mfds. Based on 0.05 mfd wound capacitor using 0.25mm (1 -mil) Film
PHYSICAL
Ultimate Tensile Strength (MD) 1.72 x 108 Pa (25,000 psi) 103 MPa (1500 psi) ASTM D882-64T
Bursting Strength Test (Mullen) 3.10 x 105 Pa (45 psi) 0.31 MPa (45 psi) ASTM 0774-63
Tear Strength - Initial 27,559 gm/mm (700 gm/mil) 35,433 gm/mm (900 gm/mil) ASTM D1004-61
Density 1.42 gm/cm3 (88.7 lb/ft3) 1.78 gm/cm3 (111.1 lb/ft3) ASTM D1505-63T
Folding Endurance(MIT) >10,000 cycles >10,000 cycles ASTM D2176-63T
THERMAL
Melting Point None None
Zero Strength Temperature 815°C (1499°F) 815°C (1499°F) Hot Bar (Du Pont Test)
Cut Through Temperature 435°C (815°F)
525°C (977°F)
435°C (815°F)
525°C (977°F)
Weighted Probe on Heated Film
(Du Pont Test)
Service Temperature -260°C to 240°C)
(-464°F to 464°F)
-260°C to 240°C)
(-464°F to 464°F)
Thermal Conductivity 0.156Wm/K
(0.09 BTU/hr-ft-°F)
0.379Wm/K
(0.219 BTU/hr-ft-°F)
Model TC-1000 Twin Heatmeter
Comparitive Tester
Flammability V-0, UL "E" card E39505 V-0, UL "E" card E39505 UL 94

Note: One mil equals .001 inch
Thermalfilm Resistance Calculator
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 mm2
 
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Thermalfilm MT Resistance Calculator
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 mm2
 
Interface Resistance =

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