Electrical Insulation Layers

Thin Plasma-Polymer Coating Systems for Electrical Insulation

© Fraunhofer IFAM
Insulating plasma-polymer coating on a Ω-coil.
© Fraunhofer IFAM
Uncoated (left) and electrically insulated (right) copper particles of 150 µm size.

Plasma-polymer coating systems for electrical insulation

Insulating layers are used to prevent electrical contact between conductive tracks as well as for protection against environmental influences and premature aging. Compared to conventional sealants and insulating coatings, plasma technology allows good partial discharge-proof insulating layers to be applied at the micrometer and sub-micrometer level.

Example applications

  • Insulating coatings on metal powders
  • Insulating coatings on conductive tracks
  • Replacement of standard insulating coatings on electronic boards and coils

The insulating layers can be applied both in-line and via a robot or traveling system at atmospheric pressure (AP)  and also using low pressure (LP) plasma processes for 3D geometries. These layers replace protective coatings and sealants, avoiding the use of solvents and drying ovens.



  • Eco-friendly coating process without solvents
  • No emission of VOCs (Volatile Organic Compounds), so fewer health & safety measures required in the workplace
  • Improved stability against aging è Time-saving and favorable-cost process
  • Efficient use of resources due to local and needs-oriented coating
  • Simplification of the production as there is no need for drying processes
  • Easy automation and process monitoring
  • Minimum coating thickness and so improved heat dissipation from components