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Thermoset Industrial Laminates

The Basics
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?
What is a
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Thermoset Plastic

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

Phenolic Resin
+ Formaldehyde + Heat . Thermoset Plastics
were born

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A

Simple

Analogy

Thermoset Plastics are like

once setthey remain set
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Cement

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Thermoplastics are like

upon the reapplication of heat they can be reshaped
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Beeswax

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Thermosetting Resins
referred to as

also

Resin Binders

1 PHENOLIC 2 EPOXY 3 MELAMINE

4 SILICONE
5 POLYESTER

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Others - POLYIMIDE

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Base Materials
as
1

also referred to

Reinforcing Substrates

Woven (COTTON) CANVAS fabric Woven (COTTON) LINEN fabric

Non-Woven (SATURATING) PAPER

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Woven (FIBERGLAS) GLASS fabric

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Industrial Laminates
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)
A-stage
uncured raw stage

B-stage
semi-cured stage

C-stage
cured stage

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Industrial Laminates tensile modulus compared with other materials

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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NEMA
National Electrical Manufacturing Association

Grades & Standards

NEMA is the regulating authority for industrial laminates

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75 years of excellence

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l

SHEETS RODS TUBES

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PANELS Accurate

P L A S T I C S, I N C.

BASIC GRADES
Canvas Base Phenolic Linen Base Phenolic Paper Base Phenolic Glass Base Epoxy Glass Base Silicone Glass Base Melamine Glass Base Polyester

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Canvas Phenolic
NEMA GRADE: Mil-I-24768/14 FBG

CE C

NEMA GRADE: Mil-I-24768/16 FBM

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Linen Phenolic
NEMA GRADE: Mil-I-24768/13 FBE NEMA GRADE: Mil-I-24768/15 FBI

LE L
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Canvas & Linen Grades Compared

under

MAGNIFICATION

Canvas

Linen
finer weave

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coarser weave

Paper Phenolic
NEMA GRADE: Mil-I-24768/12 PBM

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NEMA GRADE: Mil-I-24768/11 PBG

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XX

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Paper Phenolic
NEMA GRADE: Mil-I-24768/10 PBE

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XXX

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Glass Epoxy
NEMA GRADE: Mil-I-24768/27 GEE-F

FR4 G10
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NEMA GRADE: Mil-I-24768/2 GEE

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Glass Epoxy

High Temp

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

FR5 G11
P L A S T I C S, I N C.

NEMA GRADE: Mil-I-24768/3 GEB

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Glass Silicone
NEMA GRADE: Mil-I-24768/17 GSG

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G7

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Glass Melamine
NEMA GRADE:

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G9 G5

Mil-I-24768/1 GME

NEMA GRADE:
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Mil-I-24768/8 GMG

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Glass Polyester
NEMA GRADE: Mil-I-24768/4 GPO1

GPO 1
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Glass Polyester
NEMA GRADE: Mil-I-24768/6 GPO3

GPO 3
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SHEET
Press Shear press Sheet Sheet Sheet sheet

B-stage pallet

Standard SHEET Sizes

l l l

36 x 48 1 48 x 96 1 48 x 48 1
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l

ROUND ROD
Standard ROD Lengths
l
SHEET ROD Lamination Direction

SHEET ROD
Turned from Sheet

48 1

MOLDED ROD
Rolled (wrapped) & Molded
Rods
Rod Roller

30 to 48
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TUBE
Roll wrapped on mandrels (steel rods) which are used to form & size the inside diameter of each tube

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Standard TUBE Lengths

Random 36 to 48

Acculam PANELS
pre-cut

Standard PANEL Sizes

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
l

Cut to size available upon request

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Selecting The Right GradeMechanical

Properties

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Acculam Selecting The Right

InsulatorDielectric & Thermal Properties

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Precision

Parts can be:

Milled Drilled Turned Sawed Sheared Punched Sanded You Know

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Typical
l l l

Industries Served
l
l l l l l l

l l l

Electronics Electrical Machinery Automotive & Trucking Metal Finishing Semi Conductor Transportation

Aviation Aerospace Chemical Computer Home Appliance Public Utilities Textile You Know Medical

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Typical
l

Applications
Relays Switches Bus Bars Standoffs Washers Arc Shields Vanes Test Boards Panels Sockets
l

l
l l l l l l l l

l
l l l

l
l l l

Coils Fuses Motors Generators Gaskets Transformers Circuit Boards Condensers Terminal Strips
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P L A S T I C S, I N C.

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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.

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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

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State of the Art Facilities

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Yonkers, NY Falmouth, Cape Cod, MA