Richard, 

I'd be more than willing to tell you what I know.  
As such, it will be fairly brief ...  <grin> 

Gaps vary greatly as you probably know according to the geometry 
of the two opposable surfaces under test.  It's all a function of 
Paschen's Law for the breakdown of *** uniform *** gaps.  
Flat opposable surfaces normal to each other will give differing 
values than say two pointed opposable geometries.  Further, a 
point opposed to a line will give yet another set of values. 

Paschen's Law can be stated as 

V(kV)= 24.2Sh +6.1(Sh)^0.5  

where: 

V is the breakdown voltage in KV
S=(293p)/760T
h is electrode spacing in cm.
p is pressure mm of mercury
T is temperature in degrees Kelvin

Now, I use from physics the fact that 3MV breaks down 1 meter of air
(STP).

Using the above equation at STP, we have 30KV/cm, which is a pretty 
good crosscheck.  And thus, 3KV @ 1mm or approx 40 mils.  Put in a 
factor of 2 for safety and you have 3KV for 2 mm or 80 mils.  Boards 
are made out of FR4 which has a Dk of approx 4.  Since this shows the 
strength of the material, we divide the 2 mm by 4 and we get 0.5 mmm 
for inner layer seperation.  Not bad for the 0.4 mm seperation
specified. 
I specified 0.5 mm for the designers.  

That's my 2.5 cents. 

Regards,  Doug

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