The Basics of Thermoset Industrial Laminates

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Thermoset

Industrial Laminates

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?

What is a

Thermoset Plastic

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Thermoset Plastics

Phenolic Resin

+ Formaldehyde

+ Heat . Thermoset Plastics …were born

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In 1906/07 Dr. Leo Baekeland experimented with Phenolic Resins.

Thermoset Plastics are like

Cement You Know It’s Right… When It’s

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A

Simple

Analogy

…once set…they remain set

Thermoplastics are like

Beeswax

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…upon the reapplication of heat

they can be reshaped

Thermosetting Resinsalso

referred to as Resin Binders

1 PHENOLIC

2 EPOXY

3 MELAMINE

4 SILICONE

5 POLYESTER

6 Others - POLYIMIDE

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Base Materialsalso referred to

as Reinforcing Substrates

1 Woven (COTTON) CANVAS fabric

2 Woven (COTTON) LINEN fabric

3 Non-Woven (SATURATING) PAPER

4 Woven (FIBERGLAS) GLASS fabric

5 Others - Graphite, Kevlar®, etc.

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Industrial laminates are made by combining these thermosetting resin binders (phenolic, epoxy, melamine,

silicone, etc). with reinforcing base materials. (canvas,

linen, glass, paper, graphite, Kevlar® etc)

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Industrial Laminates

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B-stage semi-cured stage

A-stage uncured raw stage

C-stage cured stage

Industrial Laminates Graphite Epoxy (thermoset plastic).....40,000,000 psi

Steel (metal).........................................30,000,000 psi

Aluminum (metal)...............................10,000,000 psi

Glass Epoxy (thermoset plastic)....…....5,800,000 psi

Polycarbonate (thermoplastic)........…......450,000 psi

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tensile modulus compared with other materials

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NEMA Acculam®

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Grades & Standards

75 years of excellence

National Electrical Manufacturing

Association

NEMA is the regulating authority

for industrial laminates

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l SHEETS

l RODS

l TUBES

l PANELS

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BASIC GRADES

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• Canvas Base Phenolic

• Linen Base Phenolic

• Paper Base Phenolic

• Glass Base Epoxy

• Glass Base Silicone

• Glass Base Melamine

• Glass Base Polyester

Canvas Phenolic

NEMA GRADE: C Mil-I-24768/16 FBM

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NEMA GRADE: CE Mil-I-24768/14 FBG

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Linen Phenolic Acculam®

NEMA GRADE: LE Mil-I-24768/13 FBE

NEMA GRADE: L Mil-I-24768/15 FBI

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Canvas & Linen Grades Compared

under MAGNIFICATION

Linen finer weave

Canvas

coarser weave

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Paper Phenolic

NEMA GRADE: X Mil-I-24768/12 PBM

NEMA GRADE: XX Mil-I-24768/11 PBG

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Paper Phenolic

NEMA GRADE: XXX Mil-I-24768/10 PBE

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Glass Epoxy

NEMA GRADE: G10 Mil-I-24768/2 GEE

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NEMA GRADE: FR4 Mil-I-24768/27 GEE-F

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Glass Epoxy High Temp

NEMA GRADE: G11 Mil-I-24768/3 GEB

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NEMA GRADE: FR5 Mil-I-24768/28 GEB-F

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Glass Silicone

NEMA GRADE: G7 Mil-I-24768/17 GSG

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Glass Melamine

NEMA GRADE: G9 Mil-I-24768/1 GME

NEMA GRADE: G5 Mil-I-24768/8 GMG

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Glass Polyester

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NEMA GRADE: GPO 1 Mil-I-24768/4 GPO1

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Glass Polyester

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NEMA GRADE: GPO 3 Mil-I-24768/6 GPO3

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SHEET

l 36” x 48” ± 1”

l 48” x 96” ± 1”

l 48” x 48” ± 1”

press

Sheet Sheet sheet

B-stage

pallet

Sheet Shear

Standard SHEET Sizes

Press

l SHEET ROD…

Turned from Sheet

Rod Roller

Rods

SHEET ROD

Lamination

Direction

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Standard ROD Lengths

l 48” ± 1”

ROUND ROD

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l MOLDED ROD…

Rolled (wrapped) & Molded

l 30 to 48 ”

Roll wrapped on

mandrels (steel rods)

which are used to

form & size the

inside diameter of

each tube You Know It’s Right… When It’s

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Standard TUBE Lengths

• Random 36” to 48”

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TUBE

pre-cut PANELS Acculam®

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l 12” x 12” ± 1”

l 12” x 24” ± 1”

l 12” x 36” ± 1”

l 12” x 48” ± 1”

l 24” x 24” ± 1”

l 24” x 36” ± 1”

l 24” x 48” ± 1”

Standard PANEL Sizes

Cut to size available upon request

Selecting The Right GradeMechanical

Properties

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Selecting The Right InsulatorDielectric & Thermal Properties

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Milled

Drilled

Turned

Sawed

Sheared

Punched

Sanded

Precision Parts can be:

Typical Industries Served

l Electronics

l Electrical

l Machinery l Automotive & Trucking

l Metal Finishing

l Semi Conductor

l Transportation You Know It’s Right… When It’s

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l Aviation

l Aerospace

l Chemical

l Computer

l Home Appliance

l Public Utilities

l Textile

l Medical

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Typical Applications l Relays

l Switches

l Bus Bars

l Standoffs

l Washers

l Arc Shields

l Vanes

l Test Boards

l Panels

l Sockets

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l Coils

l Fuses

l Motors

l Generators

l Gaskets

l Transformers

l Circuit Boards

l Condensers

l Terminal Strips

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General & Electrical

Insulation Applications

All laminate grades & forms find uses in many electrical equipment

assemblies as spacers, shields, stand-offs, & structural supports. They

provide insulation-both thermal & electrical- for generators, arc chutes,

switchgear, brush holders, fuse cartridges, etc.

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Cryogenic, magnetic, laser applications:

G10 & G11 are the strongest of laminate materials and have excellent

stability in the presence of water, chemicals, solvents & good-both high &

low thermal resistance. These properties allow uses in cryogenic,

magnetic , laser, chemical assemblies. G10 tubing serves as rocket motor

casings for pilot ejection seats & a variety of military applications.

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High temperature electric arc furnace and welding applications: Grade G7,

G11, G9 & G10 tubing and sheet material find use in electrode insulating

plates, coil forms & bus insulation. G7, G10 & G11 tubing provide casings

for induction heating impeders & Mig welding tip insulation.

Heavy Equipment & Transport Vehicles:

Acculam thermoset composites exhibit good wear characteristics in contact with

metals under pressure and various temperature conditions. Canvas and linen

phenolics are used in heavy equipment and transport vehicles as race bearing,

flanges, gears, hydraulic wear rings, etc. Other grades, such as G10 & GPO provide

excellent electrical insulating and mechanical strength in isolating metal parts,

shims for 3rd rail insulators, and even as light weight replacements for metals.

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Gaskets, thermal barriers, insulating spacers:

G10, G11, G7, L, C, X & XX sheet & tube finds applications as gaskets,

thermal insulation , and spacers in oil, gas, water & various pipeline

applications as well as in motors, carburetors, etc. where both strength & seal

capability are needed.

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Decorative Applications

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More Applications

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More Applications

State of the Art Facilities

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• Yonkers, NY

• Falmouth, Cape Cod, MA