Teonex®

Teonex® film – High-performance PEN film for demanding applications

In today’s industry, developers of electrical systems face the challenge of finding insulation materials that offer high temperature resistance, excellent electrical properties and economic efficiency. While conventional PET films often reach their limits and high-performance polymers such as polyimide (for example, Kapton) are prohibitively expensive, Teonex film has established itself as the ideal solution for these requirements.

What exactly is Teonex® film?

Teonex film is a biaxially oriented PEN film (polyethylene naphthalate) from Teijin Film Solutions, characterized by exceptional performance properties. The name Teonex stands for a special family of PEN films that are manufactured through a controlled biaxial stretching process, giving them their characteristic mechanical and thermal properties.

The special molecular structure of PEN differs from conventional PET polyester films. While PET is based on terephthalic acid, PEN uses naphthalene dicarboxylic acid, which leads to higher temperature resistance and improved barrier properties. These structural differences position Teonex PEN films between cost-effective PET films and high-priced polyimide films such as Kapton.

In addition to the standard type Teonex Q51, there are modified types for special requirements. All variants meet temperature class F 155 °C, which enables a continuous operating temperature of 155 °C – a decisive advantage over standard insulation materials.

Manufacturing takes place under strictly controlled conditions, whereby precise temperature control and stretching parameters are crucial for the consistently high quality of the final film.

Advantages of Teonex® PEN films

The superior properties of Teonex film manifest themselves in several critical performance areas, which are of crucial importance for demanding electrical applications, among other things.

The higher temperature resistance compared to PET films allows use at temperatures up to 160 °C mechanically and 180 °C electrically. This extended temperature index makes Teonex the ideal choice for high-performance transformers and capacitors, as well as modern wide-bandgap semiconductor applications and silicon power transistors, where higher operating temperatures are the norm.

The excellent dielectric strength of up to 300 kV/mm significantly exceeds the dielectric strength of many competing insulation materials. This high dielectric strength in combination with the UL 94 VTM-2 classification ensures reliable insulation even in high-voltage applications.

A particularly important aspect is the 4 times higher hydrolysis resistance compared to PET. This improved moisture absorption resistance leads to a longer service life and more stable function in humid environments, which is particularly critical for battery packs and battery modules.

The low shrinkage of only 0.1–1.0% (depending on temperature and time) and the high mechanical strength ensure dimensional stability even under thermal cycles. These properties are crucial for the long-term safety and overall performance of the insulation system.

The balanced price-performance ratio between PET and Kapton makes Teonex an economically attractive alternative that meets both technical requirements and remains budget-friendly.

Suitable for these application areas

The versatile properties of Teonex PEN films predestine them for a wide range of critical applications in electrical engineering and beyond.

In electric motors, Teonex acts as a high-quality insulation material for slot and phase insulation. The combination of high temperature resistance and excellent dielectric strength ensures reliable function even under extreme loads. This is particularly important for high-performance motors, where conventional insulation materials would fail.

Transformers and capacitors benefit from the superior dielectric strength and low dielectric losses of Teonex. The stable performance over a wide temperature range makes this film the first choice for critical energy applications.

UL Class F insulation systems with a 155 °C continuous operating temperature are made possible by the inherent properties of Teonex. This classification opens up new possibilities for more compact designs and higher power densities in electrical systems.

High-voltage applications and electromobility systems place extreme demands on insulation materials. Teonex PEN films offer the necessary reliability and safety at moderate costs – a decisive factor for the commercial viability of these technologies.

Power electronics and modern wide-bandgap semiconductor systems require insulation materials that function stably at higher temperatures and voltages. The properties of Teonex make it the ideal insulation material for these future-oriented technologies.

Industries and applications for Teonex® films

The versatile application possibilities of Teonex film extend across numerous industries in which the highest quality and reliability are required.

In electrical engineering and electronics, Teonex PEN films have established themselves as the preferred insulation material for motors and generators. The excellent temperature stability and electrical properties enable more compact designs and higher power densities, which is particularly advantageous in modern drive technology.

The automotive industry, especially in the field of e-mobility and hybrid vehicles, places extremely high demands on insulation materials. Teonex PEN films meet the strict automotive standards and at the same time offer the cost-effectiveness required for large-scale applications.

In energy technology, Teonex films are used in solar and wind power plants as well as DC/DC converters. The long-term stability and weather resistance are decisive factors here for the profitability of the plants over their entire service life.

Medical technology benefits from the clean processing properties and chemical resistance of Teonex. Temperature-resistant insulations in medical devices must meet the highest safety standards, which is guaranteed by the certified properties of Teonex.

Aerospace applications require materials with extreme reliability at minimal weight. Teonex PEN films offer an excellent alternative to heavy insulation systems without having to compromise on performance.

In telecommunications, the dielectric properties of Teonex enable its use in high-frequency applications, where signal integrity and low losses are critical.

Processing and confectioning of Teonex® films

Our comprehensive processing capacities enable us to supply Teonex PEN films in almost any desired shape and specification. The available film thicknesses range from 12 µm to 250 µm, covering practically all industrial application requirements.

The wide range of delivery forms includes rolls up to 1,020 mm wide, as well as precise Sheets according to customer specifications for special applications. This versatility in confectioning enables our customers to obtain exactly the components that are optimized for their specific application.

Further processing into adhesive tapes and laminates opens up additional application possibilities. By combining Teonex with adhesion-promoting layers or other carrier materials, composite materials are created with tailor-made properties for special adhesive technology requirements.

Combinations with fiber materials and other carrier materials significantly expand the property profile. These laminates combine the thermal and electrical advantages of Teonex with the mechanical strength of the carrier materials, creating solutions for the most demanding applications.

Our roll-to-roll processing under partially cleanroom-like conditions enables economical production even with the highest quality requirements. Continuous process monitoring and quality control ensure consistent product quality, even for extensive orders.

Teonex® product variants in our range

The Q51 Teonex represents the standard biaxially stretched PEN film with low haze and offers the optimal balance between performance and cost-effectiveness. This variant is ideally suited for most standard insulation applications and forms the backbone of our Teonex range.

The technical data are specified in detailed data sheets, which contain all relevant parameters for material selection. These include mechanical, thermal and electrical properties as well as processing recommendations and RTI values (Relative Temperature Index).

The selection of the appropriate Teonex variant is based on the specific requirements of the respective application. Factors such as operating temperature, electrical load, mechanical stress and environmental conditions are incorporated into the optimization of material selection.

Our experienced team offers comprehensive advice on the optimal film selection. By analyzing customer-specific information and requirements, we can recommend the ideal material and processing solution.

The continuous development of new variants and formulations ensures that our range always meets the latest market requirements. Through close cooperation with Teijin and other partners, we remain at the forefront of technological development.