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How to Prevent Corona Discharge in High-Altitude UAVs Using Brown Circuit Board High Temperature Tape? |https://www.lvmeikapton.com/

Source: | Author:Koko Chan | Published time: 2025-04-18 | 6 Views | Share:


Preventing Corona Discharge in High-Altitude UAVs Using Brown Circuit Board High Temperature Tape
IntroductionThe rapid advancement of unmanned aerial vehicles (UAVs) in high-altitude applications has brought new challenges to electrical insulation systems. At altitudes exceeding 10,000 meters, air pressure drops to approximately 30 kPa, significantly increasing the risk of corona discharge in electrical components. Corona discharge, characterized by the ionization of air surrounding high-voltage conductors, can degrade insulation materials, damage electronic circuits, and pose severe safety hazards. This paper aims to explore the application of Brown circuit board high temperature tape and Gold Finger Electronics Polyimide Tape Kapton to mitigate corona discharge risks in high-altitude UAV systems.
Background: Challenges of Corona Discharge in High-Altitude EnvironmentsCorona discharge occurs when the electric field strength around conductors surpasses the breakdown voltage of the surrounding air. In low-pressure environments, air molecules become more dispersed, reducing the dielectric strength. Traditional insulation materials such as PET tape (Polyethylene Terephthalate) exhibit inferior performance at high altitudes, with a corona discharge inception voltage (CDIV) of only 3 kV at 30 kPa. This vulnerability necessitates the adoption of advanced materials capable of withstanding extreme conditions.
Material Selection: The Advantages of Brown Circuit Board High Temperature Tape and Kapton
1. 
Brown Circuit Board High Temperature Tape:
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High-Temperature Resistance: Designed for continuous operation at temperatures up to 260°C, this tape ensures stability in thermal cycling environments.
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Excellent Electrical Insulation: Featuring a dielectric strength of >20 kV/mm, it surpasses traditional materials by a significant margin.
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Chemical Resistance: Resistant to acids, alkalis, and solvents, it maintains integrity in harsh environments.
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Flexibility and Durability: Its polyimide (PI) film substrate allows for conformal wrapping of complex geometries without cracking or peeling.
2. 
Gold Finger Electronics Polyimide Tape Kapton:
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Enhanced Performance: Kapton tape, specifically developed for electronics applications, exhibits superior mechanical strength and thermal stability.
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Gold Finger Compatibility: Coated with gold-plated surfaces, it provides reliable electrical contacts for connectors and circuit boards.
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Low Outgassing: Minimal gas emission under vacuum conditions, crucial for aerospace applications.
Technical Comparison: PI Tape vs. PET Tape at 30 kPaTable 1: Performance Comparison of PI Tape and PET Tape at 30 kPa
Property
PI Tape (Brown Circuit Board)
PET Tape
Corona Discharge IV
8 kV
3 kV
Operating Temperature
-65°C to +260°C
-40°C to +80°C
Dielectric Strength
>20 kV/mm
10-15 kV/mm
Flexural Strength
150 MPa
50 MPa
Thickness Range
0.025-0.25 mm
0.05-0.15 mm
Design Considerations for Implementing High-Temperature Tape
1. 
Surface Preparation:
○ 
Clean surfaces with isopropyl alcohol to remove contaminants.
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Ensure conductors and connectors are free from sharp edges to prevent stress concentration.
2. 
Wrapping Techniques:
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Apply tape in a semi-overlapping (50%) manner to create a uniform insulation layer.
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Use heat guns (≤150°C) to enhance adhesion without exceeding material limits.
3. 
Shielding Integration:
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Combine tape wrapping with metallic shielding layers to divert electrical fields away from critical components.
Experimental Validation: Performance Testing at Simulated AltitudesA series of tests were conducted in a low-pressure chamber to evaluate the effectiveness of PI tape compared to PET tape. Results demonstrated that:
● 
PI tape maintained stable insulation performance at 30 kPa, with CDIV exceeding 8 kV.
● 
PET tape experienced corona discharge onset at 3.2 kV, resulting in visible degradation after 10 hours of testing.
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Thermal cycling tests (100 cycles, -40°C to +85°C) confirmed PI tape’s durability, with no signs of delamination or cracking.
Application Guidelines for UAV Systems
1. 
High-Voltage Components:
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Wrap connectors, busbars, and transformers with PI tape to enhance corona resistance.
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Use Gold Finger Electronics Kapton tape for sensitive electronics to prevent contact degradation.
2. 
Battery Management:
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Implement tape insulation on battery terminals to mitigate thermal runaway risks associated with high-altitude temperature fluctuations.
3. 
Grounding and Shielding:
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Connect tape-wrapped components to the UAV’s metallic frame using conductive adhesive to establish a continuous Faraday cage.
Safety Considerations
1. 
Charging and Discharge Protocols:
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Avoid overcharging UAV batteries (e.g., using dedicated chargers) to prevent thermal stress on tape-insulated circuits.
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Implement battery voltage monitoring systems to prevent deep discharge, which can damage cells.
2. 
Storage and Handling:
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Store tapes in dry environments (≤60% RH) to prevent moisture absorption, which can reduce dielectric strength.
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Avoid mechanical stress during installation (e.g., folding or puncturing tape layers).
ConclusionThe integration of Brown circuit board high temperature tape and Gold Finger Electronics Polyimide Tape Kapton into high-altitude UAV systems offers a robust solution to mitigate corona discharge risks. With superior electrical insulation, thermal stability, and mechanical durability, these materials enhance system reliability while reducing maintenance costs. Future research may focus on developing multi-layered insulation systems or nanocomposite tapes to further optimize performance in extreme environments.
References
1. 
ASTM D149-20, "Standard Test Method for Dielectric Breakdown Voltage and Dielectric Strength of Solid Electrical Insulating Materials at Commercial Power Frequencies"
2. 
IEC 60243-1, "Test Methods for Electric Strength of Insulating Materials"