an introduction to thermosets - msc plastics...agenda: how are they made what are thermosets types...
TRANSCRIPT
An Introduction to Thermosets(or there really isn’t a material called
G-10 Phenolic)
DR. LEO BAEKELAND
Invented Bakelite in 1907 which was the first phenolic…
…fast forward 107 years and Baekeland’s invention is found in many applications:
Power generation
Knife handles
Aerospace
Oil & Gas
Semiconductor
Electrical equipment
Defense
Agenda:
How are they made What are thermosets Types of thermosets
o FR4/G-10o G-11o G-9o G-7o Phenolic (canvas, linen and paper)
Shapeso Tubeo Rodo Sheet
Mil and NEMA specifications/down certing Common errors/misconceptions of thermosets Thermosets in the marketplace
Manufacturing slides courtesy of Norplex
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
“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 meetNEMA standards for specific gravity, tensile, compressive and flexural strength, minimum dielectric properties and a host of other physical characteristics. If itdoesn’t meet these mins, the material won’t meet NEMA or your customer’s print.
NEMA/MIL Specifications
Typical ApplicationsElectrical applications, terminal boards, structural parts, insulators, etc.
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)
FR4/G-10 Glass Epoxy
FR4 has the chemical element Bromine (a Halogen) or othernon-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 inthe 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 substituteone for the other
G-10 or FR4: What’s the difference?
G-11 Glass EpoxyMIL-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 ApplicationsG-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)
G-7 SiliconeMIL-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 ApplicationsG-7 as the highest rated temperature can be used in all applications where other thermosets can’t reach, such as heating & appliance insulation.
G-9 Glass MelamineMIL-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 ApplicationsArc barriers, structural parts, welding, circuit breaker components, specialty terminal blocks, switchboard panels.
Three Types of Phenolic
Paper (XX, XXX)
Linen (L/LE)
Canvas (C/LE)
A Couple of Tips:
XX is used for mechanical applications. XXX is the electrical grade and is about50% more expensive.
The “E” in LE and CE stand for“Electrical” grade.
They all look the same?How do you tell them apart?
Paper Phenolic
Paper phenolic is easy to identify withits smooth textureor finish.
Paper Phenolic
Applications
Mechanical Grade: Punch parts, jigs, templates, washers, high humidity appsElectrical Grade: Low power apps, switchgear, oil filled transformers
Linen Phenolic
Linen phenolic is easy to identify withits fine weave or finish.
Linen Phenolic
Applications
Mechanical Grade: Gears, terminal boardsElectrical Grade: Low power apps, switchgear, oil filled transformers
Canvas Phenolic
Canvas phenolic is easy to identify withits coarse weave or finish.
Canvas PhenolicApplications
Mechanical Grade: Gears, spacers, structural parts, pulleys, sheaves, rollersElectrical Grade: Combination of electrical & mechanical properties
C vs. CE
Test Measure C CE
Water Absorption % 3.50 2.00
(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) 3.10/2.70 1.70/1.50
(0.500") Condition E-48/50
Lengthwise/Crosswise
Bonding Strength
(0.500") Condition A lb 2500 1700
Condition D-48/50 lb 2300 1700
Thinking about down certing from CE to C? As Lee Corso says, “Not so fast, my friend.”
L vs. LEL LE
Water Absorption % 2.30 1.90
(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) 1.70/1.35 1.35/1.10
(0.500") Condition E-48/50
Lengthwise/Crosswise
Bonding Strength
(0.500") Condition A lb 2000 1900
Condition D-48/50 lb
Compressive Strength
(0.500") Flatwise psi 38000 36000
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?
Thermoset Shapes
Sheet
Rod
Tube
Hex Rod?
What to look for in sheet…
Typical sizes:36" x 48"48" x 48"48" x 96"
NEMA thickness tolerances can beas high as +/- 10%
Example: .125 G-10 sheet is+/- .012" or .113" to .137"!
If you have critical thicknesstolerances the best way to achievethem is through sanding.
Standard MIL spec: MIL-I-24768
What to look for in tube…
No typical sizes/almost nearly alltube is made to order
Expect longer lead times with tube
Typical lengths are 36" to 48" long
Mil-P-79
Generally no concentricity call-outfor tubing. Buyer Beware!
What to look for in rod…
Two types:Sheet rodMolded 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 tighterthan standard NEMA tolerances for sheet or molded rod
Availability:.062" to 6.00" diameter
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
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
Common errors seen in thermosets
Selling to Machine Shops
TargetLocal machine shops, fabricators and converters
WhyEasy 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.
MaterialFR4/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”)
ApplicationsFrom washing machines to the space shuttle!
Selling to Aerospace & Defense
TargetAerospace OEMs, defense industry, A & D suppliers
WhyAerospace has long been a traditional user of thermoset materials in their applications
MaterialFR4/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?!)
ApplicationsBraking systems, structural reinforcement for floors, walls and window frames, Insulation (thermal and electrical including reducing frequency crosstalk)
Selling to Power GenerationTargetPower Generation: generators, transformers, power plants
WhyThe 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.
MaterialFR4/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).
ApplicationsComponents that must have high compressive, flexural and shear strength. They require low creep and retain their electrical insulation capabilities at continual high temperatures.
Excellent for static mechanical applications requiring:
o High mechanical properties
o Electrical insulation
o Low moisture absorption
o High flexural strength
o High compressive strength
o Low Cost
o High temperature stability
o High load bearing capability
Laminates:Value in the Marketplace
Laminates:What is the Marketplace
Target industries should include:
o Machine shops
o Aerospace/Defense (multiple SIC codes)
o Power generation (multiple SIC codes)
o Semiconductor (SIC 3825)
o Switchgears (SIC 3613)
o Knife handles
o Welding equipment (SIC 3548)
o Transformers (SIC 3612)
o Electrical equipment
o Transportation
o X-Ray tables (SIC 5047)
Thank You!
IAPD members buying from other IAPD members makes
us a much stronger organization.
Mark MushNational Sales [email protected]
(269) 615-9624
I DON’T ALWAYS BUY PLASTICS
BUT WHEN I DO,I BUY FROM IAPD MEMBERS. BUY PLASTICS MY FRIENDS…