Propellis
In industries with constant product evolution, today’s electrical engineers and designers face a unique challenge – material selection. Rigid composites, as defined by NEMA, have been an industry staple in electrical insulation applications for years.
Materials such as GPO3, G10, FR4, and G-11 are especially effective choices in both high and low-voltage applications. However, as weight, form factor, and volume manufacturing increasingly become critical factors, these traditional materials may be Ill-suited to some applications for the following reasons:
Profile – Materials with thicknesses less than 0.010” are susceptible to performance variability. Dielectric and mechanical strength are critical properties with inconsistent results at thinner profiles.
Weight – Some traditional composite materials require more material to achieve optimal performance. This increased material thickness also increases weight and can be disadvantageous, particularly in e-mobility applications.
Manufacturing – In high-volume manufacturing, composite materials with thicknesses 0.010” or greater often cannot be converted using traditional flexible and elastomeric manufacturing techniques, such as die-cutting or thermoforming. These parts require machining, which leads to higher set-up and run times.
Composites may be superior in some respects, but thermoplastic films can offer an attractive alternative solution with a degree of relief in thickness, weight, and cost. However, thermoplastic material is not equivalent and not without drawbacks. Any economical thermoplastic option has the potential to melt in high-temperature environments, which is especially problematic in enclosed applications such as battery storage.