Flexible Heater PI Film Coverlay (NPC) is composed of our high dimensional stability, low-CTE polyimide film pre-laminated with a high heat-resistant thermosetting epoxy adhesive (room temperature type), providing an excellent balance of good initial adhesion (quick stick) and good shear holding power. It offeres reliable electrical insulation and environmental protection for flexible heater circuits operating under continuous high temperatures. This pre-laminated construction ensures uniform bonding quality, excellent process consistency, and long-term reliability for flexible heater insulation.
Designed for continuous operation at elevated temperatures, NPC delivers outstanding low heat shrinkage, low thermal expansion, and strong adhesion stability, effectively minimizing thermal stress, warpage, and interlayer delamination during prolonged heating and repeated thermal cycling. The high-performance TSA adhesive maintains its mechanical strength and dielectric integrity under sustained high-temperature exposure, without softening or adhesive flow.
It is well suited for applications where thermal reliability, safety, and uniform heat distribution are critical, including electrical warming devices, Automotive ADAS Camera or sensor heaters, EV battery systems, UAVs & Drones, and Outdoor Surveillance Cameras.
Engineers designing flexible heaters commonly face the following challenges when selecting coverlay materials:
Adhesive softening or loss of bonding strength at elevated temperatures
Delamination after prolonged heating cycles
Coverlay shift or edge lifting affecting heater uniformity
Reduced insulation reliability under long-term thermal stress
Premature failure despite electrically sound heater designs
In many cases, heater failure is not caused by the heating element itself, but by adhesive fatigue and coverlay instability.
NPC PI Coverlay is engineered with a focus on thermal endurance and adhesive stability, featuring:
TSA-based adhesive system
Designed to maintain strong bonding strength during continuous operation up to 150 °C
Stable adhesion under prolonged heat exposure
Preventing delamination and coverlay movement during long-term use
Consistent insulation and protection
Supporting reliable electrical isolation in flexible heater structures
Compatibility with heater manufacturing processes
Suitable for lamination and forming processes used in flexible heating pads
Unlike conventional PSA-based coverlays, NPC is designed to perform as a thermally stable, long-life coverlay solution rather than a short-term protective layer.
As illustrated, PI Coverlay NPC is integrated as the insulation and protection layer in flexible heating pads, providing enhanced adhesion stability, electrical safety, and long-term thermal reliability.
EV Battery Thermal Management: Used in battery heater foils to maintain optimal operating temperatures for electric vehicle cells.
Interior Comfort Heating: High-durability protection for seat heaters, steering wheel warmers, and armrest heating elements.
Sensor Protection: Encapsulating flexible sensors used in ADAS and engine management systems.
Temperature-Controlled Sensing Platforms : Heating substrates supporting stable sensing conditions in analytical devices.
De-Icing Systems: Integrated into flexible heating mats for aircraft wings, sensors, and windshields.
Wearable Tech: The structural foundation for smart clothing and heated outdoor gear.
3D Printers: High-temperature insulation for flexible heated build plates.
Cross-sectional structure of a ring-type flexible heater featuring Polyimide Film Coverlay (NPC) with embedded copper heater pattern for uniform thermal performance and high reliability.
A customer-implemented black flexible heater developed on our NPC and BPC polyimide film coverlays, providing reliable thermal performance, electrical insulation, and flexible integration for compact assemblies.
Contact us to discuss NPC PI Coverlay solutions tailored for your heating profile, operating temperature, and reliability requirements.
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