Composite Material Technology for Electrical Applications
Thermoset Composites for Electrical Devices and Applications
Norplex-Micarta finds its roots in the electrical industry, over 100 years ago. From those early days until now, thermoset composites have proven their value as mechanical structures that do not conduct electricity.
These properties are derived from the nature of the components in the composite. The two major components are the resin matrix and the reinforcement. By selecting these for the specific application and use conditions, thermoset composites offer a wide design window with the added benefit of affordable mass production.
Norplex-Micarta first produces prepreg. This material is the combination of a resin matrix and a reinforcement. Prepreg is then further processed into its final cured form: sheets, or shapes.
The process of manufacturing thermoset composites at Norplex-Micarta relies on state-of-the-art process automation controlling a variety of different types of equipment. The first step is to treat a reinforing substrate by impregnating it with a compounded resin.
Once the reinforcement is saturated, excess resin is removed and the combined materials are transported through an oven where it’s partially cured and becomes a Pre-Preg. Utlizing either horizontal and vertical impregnation machines, each style having its own advantages, a Pre-Preg suitable for subsequent processing is produced.
Advanced, real time, quality checks are performed on the prepreg to assure the material achieves and maintains properties essential to the sucessful downstream process. Quality Control dovetails with the manufacturing processes every step of the way through the factory.
Sheet grades are available in a variety of substrates and compounded resin combinations. We also offer products in which unlike Pre-Pregs are pressed together usually to achieve surface characteristics that differ from a material made solely from the core material.
The fiberglass based sheet offering consists of woven glass fabric combined with phenolic, epoxy, melamine or silicone resins. We offer products complying with MIL-I-24768/ and NEMA FR-4, FR-5, G-3, G-5, G-7, G-9, G-10 and G-11 requirements.
The cotton based sheet offering consists of canvas or linen grade fabric combined with phenolic or melamine resins. We offer products complying with MIL-I-24768/ and NEMA C, CE, CF, L and LE requirements.
The paper based sheet offering consists of kraft or cotton paper combined with phenolic or epoxy resins. We offer products complying with MIL-I-24768/ and NEMA X, XX, XP and XPC requirements.
Convolute rolled composite tubing grades are available in a variety of resin and substrate systems.
Fiberglass tubes consist of fine or medium weave glass reinforcement combined with an epoxy, phenolic, melamine, or silicone resin system. Meeting the requirements of ML-I-24768 and NEMA G-5, G-7, G-9, G-10, or FR-4, these grades offer a variety of properties, including high temperature resistance, excellent electrical and mechanical properties, and arc and flame resistance, depending upon the resin system selected.
These products are designed for applications requiring high electrical and mechanical strength and the ability to withstand harsh environmental conditions.
Composite tubing grades are also available with fine or medium weave cotton fabric reinforcement with a phenolic resin system. Meeting the requirements of ML-I-24768 and NEMA C or LE, these composite materials are used in mechanical applications where electrical strength is of secondary importance. Some grades include self lubricating modifiers for mechanical and friction reduction applications.
Norplex-Micarta provides a host of molded products, combining paper, cotton, and glass fabric substrates with phenolic resin, epoxy resin, or melamine resin. Applications include electrical device, mechanical, military, and power generation.
Paper phenolic rolled and molded rod products consist of various paper-based reinforcements with phenolic resin systems. The grades offer a variety of properties, including good electrical and physical strength. Meeting the requirements of NEMA XX or XXX, the products are designed for electrical applications in which mechanical strength is of secondary importance.
Cotton fabric substrate rolled and molded rod products consist of fine- to medium-weave cotton reinforcement with phenolic, epoxy or melamine resin systems. Meeting the requirements of NEMA L, LE, C, or CE, these composite materials are used in mechanical and electrical applications where electrical strength is of secondary importance. Some grades include self-lubricating modifiers for mechanical applications. Additional grades are offered that are not recognized in rod form by NEMA or the military.
Glass fabric substrate rolled and molded rod products consist of fine-to medium-weave glass reinforcement with epoxy, phenolic, or melamine resin systems. The grades offer a variety of properties, including high-temperature resistance, high electrical and mechanical strength, and arc and flame resistance. Meeting the requirements of ML-I-24768 and NEMA G-3, G-5, G-10 or FR-4, the products are designed for applications requiring high electrical and mechanical strength and the ability to withstand harsh environmental conditions. Additional grades are offered that are not recognized in rod form by NEMA or the military.
Norplex-Micarta also manufactures molded ripple springs and wedges for the power generation industry. Made from materials with excellent insulation properties and maximum creep resistance, they have the ability to withstand extreme compressive forces in high temperature environments for both generators and transformers.