Power Distribution System
Situation
To keep a power distribution system from becoming a hazardous electrical conductor, a market-leading global manufacturer of NEMA type electrical control products challenged Formtech to develop a plastic extrusion that would function as a back panel insulator.
Challenge
This product was to satisfy multiple customer needs:
- The customer wanted to reduce the cost of the backplane insulator. It was necessary to explore the redevelopment of the part using a comparable but less expensive material to realize a reduction in manufacturing costs.
- The alternative material had to maintain the same UL specifications and electrical properties as the current Polyphenylene Oxide (PPO) resin.
- The alternative resin had to be processed with a high level of dimensional stability.
Solution
Formtech's engineers began the process by exploring the characteristic properties of various alternative resins:
- The alternative material determined to have the most similar combination of properties was Polycarbonate (PC). It met the UL standards and provided a cost advantage over the PPO resin.
- The grade of Polycarbonate selected had a higher Melt Flow index (less stiff) than the original PPO resin, so an alternative sizing technique had to be developed.
- Formtech’s engineers implemented a new sizing technique that enabled them to produce the part using Polycarbonate, while maintaining the high level of dimensional stability required for the application.
Results
Formtech rose to the challenge:
- Formtech was able to produce the power distribution system back panel insulator at a reduced cost.
- The Polycarbonate part met the UL specification guidelines and maintained the electrical properties of the original Polyphenylene Oxide product.
- Formtech’s engineers were able to develop a sizing technique that enabled them to process the Polycarbonate resin with exceptional dimensional stability