Kapton-insulated wiring offers an innovative solution for electrical systems required to operate under extreme temperatures or with low outgassing thresholds. Based on a proprietary space-age polymer and conventional insulated conductor configurations, Kapton wires are well-suited for vacuum system cabling, connectors, and accessories.
Allectra produces and supplies insulated Kapton wires for high-vacuum and ultra-high vacuum (HV/UHV) environments. These wires range from ultra-thin variants suitable for use in sensitive equipment to those capable of handling high-voltage or current applications.
Allectra also provides coaxial cables, ribbon-type wires, single- and multi-strand wiring, as well as various other formats, all encapsulated with high-performance Kapton insulation. This ensures the fulfillment of a wide spectrum of end-user requirements, from cost-effective traditional solutions for budget-conscious process managers to durable, radiation-resistant Kapton wires for demanding UHV applications.
This article will offer an overview of the history and characteristics of Kapton insulation.
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Brief History of Kapton Wires
Material scientists and structural engineers are consistently tasked with balancing essential thermomechanical properties that may appear mutually exclusive. For example, simultaneously enhancing mechanical stability while minimizing the weight profiles of finished parts is a crucial goal in a broad cross-section of research and development (R&D) applications.
Addressing thermally induced fluctuations in electrical performance is another significant area of study. Each of these long-term thermomechanical challenges is foundational to the development of Kapton.
Kapton was developed by DuPont in the 1960s through a process called step-growth polymerization of novel dianhydrides. By utilizing advanced fine chemicals in this manner, a flexible polyimide was produced with exceptional thermodynamic stability across an unprecedented temperature range (4 – 637 K), along with low weight and remarkable dielectric properties. This combination of features made Kapton an ideal fit for insulating high-current wires.
The initial users of Kapton wires were the aerospace and aviation industries, where high weight-to-performance ratios are crucial for success. However, the polyimide began to exhibit a tendency to degrade in hot, humid environments characterized by routine vibration. This presented a costly challenge for aircraft manufacturers, as Kapton wiring was considered largely unsafe by regulators such as the Federal Aviation Administration.
Kapton Wires in Vacuum Environments
In the absence of humidity and with minimal chafing, Kapton wires can deliver long-term performance across a demanding temperature range. This explains their success in vacuum environments and their continued competitive edge in spacecraft engineering, despite being gradually phased out of aircraft applications.
The founders of Allectra played a significant role in introducing Kapton-insulated wires to the vacuum industry. The successful adoption of Kapton insulation by national space agencies, such as NASA, has fueled the increased usage of Kapton wires in demanding environments such as vacuum processing and research. Allectra continues to meet the demand for Kapton-insulated cables, in-vacuum connectors, and HV/UHV application connectors with a comprehensive product range.
This information has been sourced, reviewed and adapted from materials provided by Allectra Limited.
For more information on this source, please visit Allectra Limited.