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Automotive application guide

Electrical insulation of wiring harnesses, motors and components

Secure sensitive electrical areas

Electrical insulation of automotive wiring harnesses, motors and components

  • Insulate cables and wiring harnesses
  • Protect coils, motors and transformers
  • Insulate capacitors and printed circuits
  • Hold wires before impregnation
  • Protect electronic boards during certain operations
  • Withstand moisture, solvents or abrasion depending on the tape chosen
  • Protect components exposed to heat
  • Secure sensitive electrical areas
Electrical insulation of automotive wiring harnesses, motors and components
Application example: insulation and protection of automotive electrical components.

Choose insulation tape according to electrical, thermal or mechanical requirements

Depending on the area of the vehicle, the tape must meet different needs: thin insulation, temperature resistance, abrasion protection, wire holding, PCB protection or visual cable identification.

Insulation of cables and wiring harnesses in technical areas

Automotive wiring harnesses must be protected against abrasion, electrical stresses, friction, vibration and sometimes heat. Polyester, glass-cloth or polyimide tapes allow protection to be adapted to the required level.

This application concerns engine-bay areas, passages near metal parts, exposed connections, sections of harness before integration and areas requiring reliable insulation or visual identification.

Insulation of cables and wiring harnesses in automotive technical areas
Risk to avoid Cable abrasion, rubbing against a metal part, local heating, insulation fault, vibration or insufficient harness identification.
Examples of use
  • Insulate a wiring harness in an engine area
  • Protect a cable against abrasion
  • Hold an electrical wiring harness in position
  • Protect a connection area exposed to heat
  • Insulate a cable near a metal part
  • Reinforce an area exposed to friction
  • Protect a section of wiring harness before integration
  • Identify a cable using coloured tape

Suitable DERFI products

L0103J L0103J 60 µm yellow polyester tape for electrical insulation and identification. L0107N L0107N 80 µm black polyester tape for discreet electrical insulation. L0108N L0108N 100 µm black polyester tape for reinforced insulation. C0109B C0109B Tissu de verre acrylique blanc, classe thermique 155°C. C0201B C0201B High-temperature silicone glass-cloth tape, class H. B0201M B0201M 55 µm high-temperature silicone polyimide tape for thin insulation and high temperatures.

Suitable DERFI machines

ZCM1000 / ZCM2000 ZCM1000 / ZCM2000 Repeat cutting of insulation tapes to a consistent length. ZCM1100 / ZCM2200 ZCM1100 / ZCM2200 Safe cutting for sensitive or controlled workstations. RT7700 RT7700 Fast dispensing of technical tapes at electrical workstations. DSH-MONO DSH-MONO Application of single-sided tapes with release liner depending on configuration.
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Protection of coils, motors and transformers

Coils, electric motors, transformers and capacitors require tapes capable of withstanding temperature, dielectric stresses and sometimes abrasion.

Polyimide, polyester and glass-cloth tapes can hold wires, bind windings, insulate connections and protect components before impregnation, encapsulation or heat treatment.

Protection of automotive coils, motors and transformers
Risk to avoid Dielectric fault, poorly held wire, overheating, abrasion, lifting before impregnation or insufficient winding insulation.
Examples of use
  • Insulate a motor coil
  • Hold wires before impregnation
  • Protect a capacitor during production
  • Provide layer insulation on a winding
  • Protect a miniature transformer
  • Bind a winding before treatment
  • Reinforce an electrical area exposed to temperature
  • Hold connections before encapsulation

Suitable DERFI products

B0201M B0201M Polyimide silicone HT 55 µm, tenue diélectrique 6 kV. B0201ML B0201ML 35 µm polyimide tape for thin and conformable applications. B0204M B0204M 180 µm polyimide tape for more robust insulation. L0103J L0103J UL510 yellow polyester tape for coil wrapping. C0109B C0109B Acrylic glass-cloth tape for mechanical and thermal insulation. C0201B C0201B Silicone glass-cloth tape for high temperatures. C0205B C0205B 200°C silicone glass-cloth tape for demanding applications.

Suitable DERFI machines

ZCM1000 / ZCM2000 ZCM1000 / ZCM2000 Preparation of repeat strips for coils and components. RT7700 RT7700 Fast dispensing at electrical or electrotechnical workstations. RT120W RT120W Dispensing wide tapes or technical materials. ZCM1100 / ZCM2200 ZCM1100 / ZCM2200 Safe cutting at sensitive workstations.
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PCB masking and protection

Electronic boards used in vehicles may require temporary masking during soldering, heat treatment, surface protection or assembly.

Polyimide tapes are particularly suitable for thin areas, electronic components, contacts, connectors and PCB surfaces requiring stable protection at temperature.

Automotive PCB masking and protection
Risk to avoid Deposits on contacts, troublesome excess thickness, unstable protection during heating, contaminated PCB area or poorly protected connector.
Examples of use
  • Mask contacts on a PCB board
  • Protect an area before wave soldering
  • Insulate a track or sensitive area
  • Protect a connector area
  • Prevent deposits on an electronic part
  • Maintain protection during heat treatment
  • Protect a board before selective conformal coating
  • Mask a test or interface area

Suitable DERFI products

B0201M B0201M High-temperature silicone polyimide tape for PCBs, soldering and insulation. B0201ML B0201ML Ultra-thin polyimide tape for low build-up. B0204M B0204M Thick polyimide tape for reinforced protection. L0104T L0104T 60 µm transparent polyester tape for insulation, PCBs and powder-coating processes. C0201B C0201B Silicone glass-cloth tape for robust protection.

Suitable DERFI machines

ZCM1000 / ZCM2000 ZCM1000 / ZCM2000 Cutting small strips to a consistent length. RT7700 RT7700 Fast dispensing of technical tapes in electronics workshops. ZCM1100 / ZCM2200 ZCM1100 / ZCM2200 Safe cutting for sensitive workstations.
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Cable identification and marking

Coloured tapes make it easier to visually identify cables, wiring harnesses, components, intervention areas or inspection elements. In an industrial environment, this improves workstation readability and reduces errors.

This application can be used to distinguish several circuits, flag a repair area, identify an electrical connection or mark an area to be checked on a wiring harness.

Automotive cable identification and marking
Risk to avoid Confusion between circuits, inspection error, unidentified cable, poorly marked repair area or lack of visible production marking.
Examples of use
  • Identify a cable or electrical connection
  • Mark a wiring harness area for inspection
  • Differentiate several circuits
  • Mark a repair or rework area
  • Indicate an insulated component
  • Create a visible splice
  • Temporarily mark a test area
  • Facilitate quality control of wiring harnesses

Suitable DERFI products

L0103J L0103J Yellow polyester tape for insulation, marking and identification. L0107N L0107N Black polyester tape for discreet insulation and understated identification. L0108N L0108N 100 µm black polyester tape for reinforced insulation. B0201M B0201M Amber polyimide tape for identification in electronic environments. Q0145U Q0145U Conductive copper tape if identification is combined with shielding.

Suitable DERFI machines

ZCM1000 / ZCM2000 ZCM1000 / ZCM2000 Repeat cutting of marking strips. RT7700 RT7700 Fast dispensing of identification tapes. ZCM1100 / ZCM2200 ZCM1100 / ZCM2200 Safe cutting for sensitive wiring workstations.
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Use case overview

Automotive electrical insulation covers the protection of cables, wiring harnesses, coils, motors, capacitors, electronic boards, printed circuits and sensitive electrical areas. Tape selection depends on the required insulation level, temperature, abrasion, required thinness and any identification need.

Key points for consumables

  • B0201M is suitable for thin, high-temperature insulation, PCB and windings.
  • B0201ML is suitable for thin electronic applications with minimal added thickness.
  • B0204M meets requirements for reinforced polyimide insulation.
  • L0103J is suitable for electrical insulation, marking and identification.
  • L0107N / L0108N are suitable for black polyester insulation.
  • L0104T is suitable for transparent insulation, PCB and powder coating.
  • C0109B meets electrical insulation requirements using glass cloth with acrylic adhesive.
  • C0201B / C0205B are suitable for high-temperature glass cloth insulation.
  • P0205 is suitable for high-temperature PTFE dielectric insulation.

Key points for workstation organisation

  • ZCM1000 / ZCM2000 allows repeated cutting of insulation strips.
  • ZCM1100 / ZCM2200 provides safe cutting at sensitive workstations.
  • RT7700 speeds up technical tape dispensing in electrical or electronics workshops.
  • RT120W is useful for wide tapes and technical substrates.
  • DSH-MONO can be used depending on the presence of a protective liner or release liner.