Product Bulletin
Thermoset Moulding
Compounds for
Commutators
Leaders Through Experience
For many decades, Bakelite® moulding
compounds from Hexion have been
used with great success in manufacturing
commutators and slip ring elements.
The experience gained over this period,
rigorous market analysis and trust-based
teamwork with processors and final users
of Bakelite® moulding compounds have
contributed to the unbroken continued
development in this field.
The increasing capacities of electric
motors coupled with unchanged or even
more compact physical dimensions lead
to ever greater thermal and mechanical
stresses on the insulating moulding
compound in the commutator. Moreover,
such motors are expected to offer even
lengthier service lives despite the increased rotational speeds and more compact
physical dimensions.
The Hexion Specialty Chemicals product
line – offering melamine-phenol and
phenol-formaldehyde moulding
compounds – is in line with these strict
requirements, and offers a wide range
of products for all common types of
commutators. Moreover, the Hexion
R&D Department unceasingly develops a
wide range of new products specifically
directed toward meeting the constantly
rising demands.
Bakelite® moulding compounds for
commutators feature:
• High adhesion to copper
• High mechanical strength
(compression fit oversize)
• Dimensional stability
• Thermal stability
• Electrical insulating ability
Moulding Compounds for Commutators
Product
Resin
Applications
PF 13
Novolak
Vacuum cleaners, power tools (for annularly
reinforced commutators)
PF 4155
Novolak
Automotive, vacuum cleaners
PF 4109
Resole, ammonia-free
Vacuum cleaners, power tools, automotive
PF 4136
Resole, ammonia-free
ABS, washing machines
PF 4285
Novolak
Power tools, ABS, automotive
MP 4165
Melamine-Phenol
ABS, automotive
Moulding Compounds for Commutators
Product
Extenders
Properties
Cu Adhesion
Tg [ °C ]
PF 13
Inorganic
Heat-resistant, UL listed
(+)
250
PF 4155
Glass fiber
Excellent base properties
(+)
260
PF 4285
Glass fiber
Excellent thermomechanical
properties
-
280
PF 4109
Glass fiber
UL listed
-
> 280
PF 4136
Glass fiber
High elongation and
dimensional stability
-
> 280
Glass fiber
Strong copper adhesion
++
250
Novolak
Resol
Melamine-Phenol
MP 4165
Moulding Compounds for Commutators
Product
HDT A -1.8 MPa [ °C ]
PF 4109
> 280
PF 4136
> 280
PF 4155
245
PF 4285
> 280
MP 4165
265
Heat Treatment
Heat treatment is used to enhance the
final properties of the commutator. In this
low-stress process, heating according to
an exact temperature program drives off
volatile components that remain in the
moulding. In addition, this process
completes curing of the moulding
compound. This particularly enhances
the
Suggested heat-treatment temperature program for copper-adhesive MP moulding compounds
°C
180
165
150
• Dimensional stability
• Temperature resistance
• Solder bath resistance
• Settling behavior of the
moulding compound
Both the selected temperature range
and the individual temperatures are key
factors in optimal heat treatment. The
best results are achieved by increasing
the treatment temperature in stages,
selecting the temperature range on the
basis of the pertinent glass transition
temperature (Tg) of the moulding
compound.
In the case of a commutator, this
treatment ensures reliable anchoring to
the axle, low brush sparking, smooth
running, temperature reserves and thus
a distinct increase in the service life.
Hexion Specialty Chemicals utilizes
ultramodern analytical methods to
precisely align the moulding compound
with the final commutator product. This
involves investigations of the raw materials,
the moulding compound itself and
application-related test articles. An
important method of analysis is differential
scanning calorimetry (DSC), with which
the curing level of the moulding
compound can be determined. Similarly,
the glass transition temperature (Tg) is
of great significance for the final product
properties. Methods including thermomechanical analysis (TMA) are used to
determine the Tg.
Commutators for:
h
5
10
15
20
25
Example of a TMA curve with computer-aided determination of the glass transition temperature
TMA
um
600,00
400,00
50,00 °C
7,41um 18,95 x 10 -6/K
150,00 °C
200,00
252,06 °C
0
0
100,00
200,00
300,00
Automotive Applications
• Industrial applications
• Automotive applications
• Power tools
• “White goods”
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Headlight alignment system
Alternator
Radiator fan
Starter motor
Ventilator
Windshield wipers
Air bag
Seat adjustment system
Central locking system
Power windows
Sunroof
ABS
Antenna
Fuel pump
The Global Leader in Thermoset Resins
As the world’s largest producer of thermoset resins and the leader in adhesive and structural resins and coatings,
Hexion Specialty Chemicals meets customers’ specific application needs with a total solutions approach of products and services.
Hexion offers the broadest range of thermoset resin technologies and unmatched technical support – and provides them around the globe.
With our extensive research and development capabilities and applications know-how, we are uniquely able to work in partnership with
customers to co-develop better products and systems.
Plus, Hexion’s worldwide production network facilitates assured supply and prompt delivery wherever our customers do business.
World Headquarters / North America:
Regional Headquarters:
Hexion Specialty Chemicals, Inc.
180 East Broad Street
Columbus, OH 43215 - 3799
+1 614 225 4000
Asia
Hexion Specialty Chemicals
Trading Co., Ltd.
Lippo Plaza # 3701
222 Central Huai Hai Road
Shanghai 200021 China
+ 86 21 3318 4800
Australia
Hexion Specialty Chemicals
Australia Pty.
2- 8 James Street
Laverton North Victoria 3026
Australia
+ 61 39 369 2377
Europe
Hexion Specialty Chemicals B.V.
Koddeweg 67
3194 DH Hoogvliet
Rotterdam, The Netherlands
+ 31 10 295 4000
Latin America
Hexion
Química Indústria e Comércio Ltda.
Rua Cyro Correa Pereira, 2525
Area-Sul – CIC
81450 - 090 Curitiba, Brazil
+ 55 41 212 1600
Hexion Specialty Chemicals B.V.
Koddeweg 67
3194 DH Hoogvliet
Rotterdam, The Netherlands
+ 31 10 295 4000
Hexion Specialty Chemicals GmbH
Gennaer Straße 2-4
58642 Iserlohn
Germany
+ 49 2374 925 0
® and TM Licensed trademarks of Hexion Specialty Chemicals, Inc.
For worldwide locations visit
hexion.com
© 2006 Hexion Specialty Chemicals, Inc. HCI - 503 09/06 Printed in Germany.
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contained herein constitutes an offer for the sale of any product.