An Introduction to Thermosets (or there really isn t a material called G-10 Phenolic)

Transcription

1 An Introduction to Thermosets (or there really isn t a material called G-10 Phenolic)

2 DR. LEO BAEKELAND Invented Bakelite in 1907 which was the first phenolic

3 fast forward 107 years and Baekeland s invention is found in many applications: Power generation Aerospace Electrical equipment Knife handles Oil & Gas Semiconductor Defense

4 Agenda: How are they made What are thermosets Types of thermosets o FR4/G-10 o G-11 o G-9 o G-7 o Phenolic (canvas, linen and paper) Shapes o Tube o Rod o Sheet Mil and NEMA specifications/down certing Common errors/misconceptions of thermosets Thermosets in the marketplace

5 Manufacturing slides courtesy of Norplex

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10 NEMA* Grade Mil Specification Type XXX MIL-I-24768/10 PBE XX MIL-I-24768/11 PBG CE MIL-I-24768/14 FBG C MIL-I-24768/16 FBM LE MIL-I-24768/13 FBE L MIL-I-24768/15 FBI G-7 MIL-I-24768/17 GSG G-9 MIL-I-24768/1 GME FR4 MIL-I-24768/27 GEE-F G-10 (true) MIL-I-24768/2 GEE G-11 MIL-I-24768/3 GEB * National Electrical Manufacturer s Association NEMA/MIL Specifications You just can t spray paint some plywood green and call it G10! In order for a material to be called G-10, G-11, LE phenolic, etc. it must meet NEMA standards for specific gravity, tensile, compressive and flexural strength, minimum dielectric properties and a host of other physical characteristics. If it doesn t meet these mins, the material won t meet NEMA or your customer s print.

11 FR4/G-10 Glass Epoxy Probably the most popular material and most well known Superior electrical characteristics, which are exhibited over a wide range of temperatures and humidity This material is extremely high in mechanical strength, has low water absorption and great insulation properties No shelf life limitations (e.g. up to 10 years in proper storage) Temperature limitation is 140 C (284 F) Typical Applications Electrical applications, terminal boards, structural parts, insulators, etc.

12 G-10 or FR4: What s the difference? FR4 has the chemical element Bromine (a Halogen) or other non-halogens as flame-retardant additives o It is not fire-proof o It is flame retardant (will burn but will self-extinguish) o It is UL rated 94 V-0 Plain G-10 does not have any flame retardant chemicals in the formula o It is UL rated 94HB (horizontal burn) FR4 meets MIL-I-24768/27* G-10 meets MIL-I-24768/2* *If the Mil Spec is called out, you can never substitute one for the other

13 G-11 Glass Epoxy MIL-I-24768/3 A grade similar in composition to FR4/G-10 but more suitable for use at elevated temperatures Retains at least 50% of its structural strength at continuous operating temperatures in excess of 180 C (356 F) Typical Applications G-11 is best used in applications where FR4 or G-10 is not an option (i.e., the temperature requirements are higher than 140 C. G-11 is typically higher cost than FR4/G-10)

14 G-7 Silicone MIL-I-24768/17 Highest heat laminate Unequaled laminate for high heat and arc resistant applications Recommended for use in applications in humid conditions in excess of 500 F Poorest bond strength 220 C (or 428 F) maximum operating temperature Typical Applications G-7 as the highest rated temperature can be used in all applications where other thermosets can t reach, such as heating & appliance insulation.

15 G-9 Glass Melamine MIL-I-24768/1 Best arc resistance & dielectric properties Radio frequency heat sealing Recommended for use where mechanical properties are needed in wet conditions Good substitute for G-5 Rigid, strong Temperature limitation is 140 C (284 F) Typical Applications Arc barriers, structural parts, welding, circuit breaker components, specialty terminal blocks, switchboard panels.

16 Three Types of Phenolic Paper (XX, XXX) Linen (L/LE) A Couple of Tips: XX is used for mechanical applications. XXX is the electrical grade and is about 50% more expensive. The E in LE and CE stand for Electrical grade. Canvas (C/LE) They all look the same? How do you tell them apart?

17 Paper Phenolic Paper phenolic is easy to identify with its smooth texture or finish.

18 Paper Phenolic Applications Mechanical Grade: Punch parts, jigs, templates, washers, high humidity apps Electrical Grade: Low power apps, switchgear, oil filled transformers

19 Linen Phenolic Linen phenolic is easy to identify with its fine weave or finish.

20 Linen Phenolic Applications Mechanical Grade: Gears, terminal boards Electrical Grade: Low power apps, switchgear, oil filled transformers

21 Canvas Phenolic Canvas phenolic is easy to identify with its coarse weave or finish.

22 Canvas Phenolic Applications Mechanical Grade: Gears, spacers, structural parts, pulleys, sheaves, rollers Electrical Grade: Combination of electrical & mechanical properties

23 Thinking about down certing from CE to C? As Lee Corso says, Not so fast, my friend. C vs. CE Test Measure C CE Water Absorption % (0.062") Condition D1-24/23 Flexural Strength psi 18,000/17,000 17,500/15,000 (0.062") Condition A Lengthwise/Crosswise Tensile Strength psi 12,700/9,700 11,000/9,000 (0.125") Lengthwise/Crosswise Izod Impact Strength ft-ib/in (notched) 3.10/ /1.50 (0.500") Condition E-48/50 Lengthwise/Crosswise Bonding Strength (0.500") Condition A lb Condition D-48/50 lb

24 The same applies when trying to down cert LE to L. There are significant differences of materials that can possibly affect performance. Do you want to take the chance the down certed material meets end user specs? L vs. LE L LE Water Absorption % (0.062") Condition D1-24/23 Flexural Strength psi 24,500/18,500 22,000/16,000 (0.062") Condition A Lengthwise/Crosswise Tensile Strength psi 14,000/10,000 13,000/9,000 (0.125") Lengthwise/Crosswise Izod Impact Strength ft-ib/in (notched) 1.70/ /1.10 (0.500") Condition E-48/50 Lengthwise/Crosswise Bonding Strength (0.500") Condition A lb Condition D-48/50 lb Compressive Strength (0.500") Flatwise psi

25 Thermoset Shapes Sheet Tube Rod Hex Rod?

26 What to look for in sheet Typical sizes: 36" x 48" 48" x 48" 48" x 96" NEMA thickness tolerances can be as high as +/- 10% Example:.125 G-10 sheet is +/-.012" or.113" to.137"! If you have critical thickness tolerances the best way to achieve them is through sanding. Standard MIL spec: MIL-I-24768

27 What to look for in tube No typical sizes/almost nearly all tube is made to order Expect longer lead times with tube Typical lengths are 36" to 48" long Mil-P-79 Generally no concentricity call-out for tubing. Buyer Beware!

28 What to look for in rod Two types: Sheet rod Molded rod Tolerances for sheet rod*: +/-.001" up to 1.25" diameter +/-.003" 1.25" to 3.00" diameter +/-.005" over 3.00" diameter *Note how sheet rod tolerances are much tighter than standard NEMA tolerances for sheet or molded rod Availability:.062" to 6.00" diameter

29 Molded or Sheet Rod? *Molded rod (on the left) has a rolled up window shade look Typically molded rod is 46" in length Sheet rod is typically 48" in length Molded rod works better than sheet rod in tubular applications due to its circumferential lamination pattern

30 Common errors seen in thermosets Can I get a quote on G-10 Phenolic? Does not exist! I need some Micarta. Micarta is a trade name. Where do I find bakelite? Obsolete trade name. Does this come in hex rod? No hex rod. Machined? I need Canvas Phenolic to come in +/-.0005" Borderline. Material can t be broached

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34 Selling to Machine Shops Target Local machine shops, fabricators and converters Why Easy to find, decision makers are often easily accessible, sales cycle is much quicker than large OEM s, can also be supplier of parts to machine shops that don t want to run thermoset parts. Material FR4/G-10, G-11, G-7, G-9, Phenolic (canvas, linen and paper) Sales Tips Know the NEMA tolerances (especially the flatness tolerances) Know the grades (difference between G-10 and FR4, Mil specs) If a machine shop doesn t touch that stuff ask if you can machine the parts for them! Ask about phenolics/glass epoxies by name (some people don t think of them as plastic ) Applications From washing machines to the space shuttle!

35 Selling to Aerospace & Defense Target Aerospace OEMs, defense industry, A & D suppliers Why Aerospace has long been a traditional user of thermoset materials in their applications Material FR4/G-10, G-11, G-7, G-9, Phenolic (canvas, linen and paper) Sales Tips Keep in mind old specs/there are many prints out there that have old specs, obsolete materials and/or outdated trade names. As with machine shops, A & D companies may not want to machine thermosets (why not you?!) Applications Braking systems, structural reinforcement for floors, walls and window frames, Insulation (thermal and electrical including reducing frequency crosstalk)

36 Selling to Power Generation Target Power Generation: generators, transformers, power plants Why The generation of high voltage or high levels of electricity demands insulated materials for both the electrical and thermal elements of this industry. Power generation is probably the largest generator of thermoset applications in the country. Material FR4/G-10, G-11, G-9 Sales Tips If a company is generating electricity they almost certainly will have a need for thermosets. The higher the voltage the more demanding the material (i.e., can t use GPO-3). Applications Components that must have high compressive, flexural and shear strength. They require low creep and retain their electrical insulation capabilities at continual high temperatures.

37 Laminates: Value in the Marketplace Laminates: What is the Marketplace Excellent for static mechanical applications requiring: Target industries should include: o Machine shops o o High mechanical properties Electrical insulation o Aerospace/Defense (multiple SIC codes) o Low moisture absorption o Power generation (multiple SIC codes) o High flexural strength o Semiconductor (SIC 3825) o High compressive strength o Switchgears (SIC 3613) o Low Cost o Knife handles o High temperature stability o Welding equipment (SIC 3548) o High load bearing capability o Transformers (SIC 3612) o Electrical equipment o Transportation o X-Ray tables (SIC 5047)

38 Thank You! I DON T ALWAYS BUY PLASTICS IAPD members buying from other IAPD members makes us a much stronger organization. BUT WHEN I DO, I BUY FROM IAPD MEMBERS. BUY PLASTICS MY FRIENDS Mark Mush National Sales Manager mark@atlasfibre.com (269)