【经验】Parker Chomerics导电塑料助力汽车行业机构零件设计革新
节能减耗,是当今汽车行业对新型汽车设计的整体要求。因此,对于汽车工程师来讲,寻求更轻型的解决方案,是一个必须的设计目标。用塑料机构件替代传统金属件,是现阶段正在进行的一次设计革新。理论上,新型的塑料注塑件,能够作为汽车行业中数百万零件的替代方案。
这种新型的注塑件替代方案,不仅能够减轻大量的零件重量,还具有明显的成本效益,可谓是一举两得。减轻重量相信大家都能理解,那么成本效益又表现在哪些方面呢?注塑件的成本效益首先就在零件模具上,内行的朋友可能会说,注塑模具比冲压或压铸模具的价格更高。没错,单从价格上看确实如此。但是,在模具成本中,除了模具价格以外,还有一个十分重要的修模成本。其中包含了模具损耗、折旧周期,以及模具修改成本。在这一点上,注塑模具就具有绝对优势,模具本身几乎不会损坏,因此损耗修补和折旧费用相当低。而且,注塑模具大多采用组合模具的方式,因此模具修改成本也很低。
在汽车行业中,一个整车平台可能对应多款车型,而每款车型都可能经历多次的零件修改和升级。根据笔者在汽车行业十五年的经验来看,一个整车平台的生命周期少则三五年,多则十几年,相关机构件的修改最多经历过四十多次。现在想来,幸亏是注塑模具,修模成本和再设计成本都比较低,如果换成压铸件,可能就是几十倍的修模费用。
而从实际应用的工艺特性上看,注塑件的组合模具方式,就决定了其具有更好的工艺灵活性。而且,注塑件更易实现一体成型,可以省去大部分的二次加工过程,工艺成本更低。注塑一体零件的优点还包括,组装工艺更简单方便,Poka-Yoke工艺防错性更好,能够降低工艺组装成本,并且提高生产效率。
在车身应用中,注塑件包括导电塑料件和非导电塑料件两大类,都有非常广泛的应用空间。其中,导电注塑件需要考虑的性能指标更多一些,增加了电气性能相关的指标,例如EMI屏蔽效能、表面电阻率、穿透电阻、耐电偶腐蚀性,等等。因此,导电塑料设计的过程会更加复杂,需要同时考虑的关键点也更多。在这种情况下,选择一个合适的供应商,可能会起到至关重要的作用。本文在这里推荐一个世界一流的导电塑料生产厂家,美国PARKER CHOMERICS(派克固美丽)公司。该公司历史悠久、技术领先,在屏蔽材料领域中具有相当丰富的市场经验和技术知识。针对导电塑料的注塑件应用,派克固美丽推荐了三大系列导电塑料产品,根据特性不同,可以用在不同的车载应用中,以下做简单的推荐介绍。
图1 PREMIER™系列导电塑料颗粒
派克固美丽推出的导电塑料颗粒为PREMIER™系列,有三个子系列,分别为PEI、PBT和PC/ABS系列:
• PREMIER™ PEI系列导电塑料,为聚乙烯酰亚胺混合物,具有相当不错的屏蔽性能、耐高温性能和耐腐蚀性能。这款产品在汽车应用中,推荐作为较大的铝质外壳替代方案,通常能够降低50~70%的重量。目前这款产品不仅在汽车行业中使用,而且还在军用车载和航空电子设备中投入使用,市场反馈十分良好。
• PREMIER™ PBT系列,在PBT塑料中加入了不锈钢纤维,以增强屏蔽效果和导电性能。该系列产品设计用来保护敏感元件,不受到电磁干扰的破坏,主要推荐的型号有PREMIER™ PBT-225和PREMIER™ PBT-250FR两款。PBT-225型,具有增强的抗水解特性,在热水和蒸汽环境中仍能保持良好的稳定性,推荐用在汽车发动机和水冷排气系统附近;PBT-250FR型,具有特殊的阻燃特性,达到UL94 5VA(2.5mm)等级,对于燃料也有不错的耐腐蚀抗性,推荐用在汽车油箱和燃油系统附近。
• PREMIER™ PC/ABS系列,为PC/ABS塑料基质,导电填料有镀镍石墨纤维和镀镍石墨粉两种。这一系列的特点是,性能全面,特性丰富多样,共有A220经济型、A230普通型和A240高性能型三款,性能从低到高。电气性能最佳的A240型,表面电阻率小于0.25Ω/sq,穿透电阻小于0.03Ω,屏蔽效能超过90dB。而且,每个型号产品都能定制各种特殊特性,包括通用温度85˚C(HT)、超高温105˚C(ST)、可燃性等级UL 94 V-0(FR)以及混合填料(HF)。这款产品可以用在车载应用的各种场合,优势在于相似的塑料粒子基质和配方,因此在多种零件的配合使用中,具有很高的材质匹配度,例如塑料热膨胀系数、电偶电位等。所以,如果在同一个整车平台下,需要设计多种导电塑料机构件,可以尽量考虑采用PC/ABS系列,提高材料性能的相似度和匹配度。
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Parker Chomerics(派克固美丽)导电特种材料选型指南
描述- Parker is the global leader in motion and control technologies, providing precision-engineered solutions for a wide variety of mobile, industrial and aerospace markets. Parker can be found on and around everything that moves.
型号- CHO-SHIELD 571,52-01-2001-0000,50-30-0584-0029,CHO-LUBE 4220,52-01-0571-0000,50-10-1086-0000,52-03-2056-0000,CHO-BOND 2165,CHO-SHIELD 608,CHO-BOND 1077,596,52-00-2002-0000,52-00-2003-0000,51-02-4669-0000,50-33-1038-0000,50-01-0584-0208,50-00-1091-0000,CHO-SHIELD 604,72-00002,72-00005,CHO-BOND 1075,52-03-2044-0000,50-05-0580-0208,50-02-1030-1000,4220,50-01-1030-0000,2044,2040,52-01-2002-0000,50-00-0584-0208,52-00-2001-0000,54-01-4220-0000,CHO-SHIELD 4994,CHO-SHIELD 2056,CHO-SHIELD 596,50-01-2165-0000,2056,52-01-0579-0000,50-01-1085-0000,52-01-0604-0000,50-04-2165-0000,52-01-0596-0000,52-04-4994-1000,52-03-0610-0000,CHO-SHIELD 2044,50-01-1075-0000,50-10-0584-0029,52-00-2002-1000,50-02-1038-0000,CHO-SHIELD 4900,50-02-1075-1000,50-00-1029-0000,50-01-1091-0000,CHO-SHIELD 2040,CHO-SHIELD 579,4994,50-00-0584-0029,CHO-SHIELD 610,CHO-SHIELD 576,72-08116,CHO-BOND 584-208,52-04-2002-0000,CHO-BOND 580-208,CHO-BOND 360-20,CHO-BOND 1029,52-01-0576-0000,CHO-LUBE E117,50-02-1038-1000,50-01-0580-0208,CHO-BOND 1035,52-04-0608-0000,51-05-4669-0000,TECKNIT 8116,50-03-0584-0029,50-02-1077-0000,CHO-BOND 4669,CHO-BOND 1038,52-04-2001-0000,50-02-1016-0000,CHO-BOND 1030,52-00-2001-1000,CHO-BOND 4660,51-00-1035-0000,2001,CHO-BOND 1019,50-00-0360-0020,50-02-0584-0029,52-03-4994-1000,50-01-1121-0000,52-00-2003-1000,604,CHO-SHIELD 1091,608,50-02-1075-0000,50-31-1038-0000,TECKNIT 0005,51-01-1035-000,TECKNIT 0002,50-04-1086-0000,50-01-1077-0000,50-01-1029-0000,51-02-4660-0000,50-02-1030-0000,571,51-05-4660-0000,576,610,CHO-BOND 1016,2003,50-01-1038-0000,54-01-E117-0200,2002,51-00-1035-1000,50-01-0584-0029,50-02-2165-0000,CHO-SHIELD 2002,52-00-0596-0000,CHO-SHIELD 2003,54-02-4220-0000,CHO-SHIELD 2001,50-01-1019-0000,52-01-2003-0000,50-01-1016-0000,CHO-BOND 1121,50-01-0360-0020,52-03-2040-0000,52-04-2003-0000,50-01-1086-0000,52-02-4900-0000,CHO-BOND 584-29,CHO-BOND 1085,CHO-BOND 1086
Parker Chomerics(派克固美丽)CHOFORM®和ParPHorm®系列EMI屏蔽垫片选型指南
目录- EMI Gaskets ParPHorm and CHOFORM Sealing Compounds CHOFORM Shielded Housing Assemblies
型号- PARPHORM L1938,CHOFORM 5560,19-26-5560-0500,PARPHORM S1945,CHOFORM 5541,19-26-1938-0200,CHOFORM®5541,PARPHORM® 1800,CHOFORM®5560,PARPHORM®1800,19-26-5528-0850,PARPHORM®L1938-45,CHOFORM® 5528,CHOFORM® 5526,PARPHORM® L1938-45,CHOFORM® 5575,19-26-5526-0850,CHOFORM 5528,CHOFORM® 5550,PARPHORM 1800,CHOFORM 5526,CHOFORM®5538,PARPHORM® S1945-25,CHOFORM®5513,PARPHORM®S1945-25,19-26-5550-0575,CHOFORM®5575,CHOFORM®5550,19-26-1800-0345,CCHOFORM 5550,19-26-5575-0240,CHOFORM® 5538,19-26-5538-0650,CHOFORM® 5513,19-26-5541-0650,19-26-5575-0500,CHOFORM® 5541,CHOFORM® 5560,CHOFORM®5528,CHOFORM 5513,19-26-1945-0250,CHOFORM 5538,CHOFORM®5526,CHOFORM 5575,19-26-5513-0850
PREMIER™ PBT-250-FR ELECTRICALLY CONDUCTIVE FLAME RETARDANT (FR) POLYBUTYLENE TEREPHTHALATE (PBT) PLASTIC
型号- PBT-250-FR,PREMIER™ PBT-250-FR,PREMIER PBT-250-FR
Parker Chomerics 产品概述
型号- CHO-TOUCH™,CHO-STRAP®,CHO-SEAL®,STREAMSHIELD OMNI-CELL® SHIELD-CELL,T-WING®,CHO-MUTE®,CHO-MASK®,SPRING-LINE®,DURALAN™,CHO-BOND®,CHO-FAB®,THERM-A-GAP™,WIN-SHIELD®,CHO-SORB®,THERM-A-FORM™,CHO-THERM®,THERMFLOW®,CHO-SHRINK®,THERMATTACH®,METALASTIC®,PREMIER™,CHO-FOIL®,CHO-LUBE,SOFT-SHIELD®,CHO-FORM®,POLA®,TECKFILM™,CHO-SHIELD®
【选型】适用于EMP防护应用的屏蔽材料类型:金属指形簧片、金属编织网、金属箔胶带、导电塑料
本文谈到的是以防EMP破坏应用为重点的产品,先简单讲一下什么是EMP,以及防EMP产品的特点。从EMP的特性出发,显然需要的就是能够在短时间内快速导出大量电磁能量的产品,并且屏蔽效能要足够高,能够衰减绝大部分的电磁能量。因此,这种EMP应用通常选择的是金属材料制品,同时保证大载流量、高屏蔽效能和高导电性能。笔者从派克固美丽产品库中,筛选了几个适用于EMP防护应用的产品类型。
器件选型 发布时间 : 2019-06-22
Speeding Development. Reducing Risk. Electromagnetic Interference (EMI) Shielding and Thermal Interface Materials Solutions for Life Science Devices
型号- PREMIER™ A240-FRHF,WIN-SHIELD™ P,SOFT-SHIELD® 4850,CHO-SEAL® 1285,PREMIER™ PEI 140,THERM-A-GAP™ GEL 30,CHOFORM® 5528,CHO-SHIELD® 2040,PREMIER™ A220-HT,THERM-A-GAP™ 974,CHO-SHIELD® 2044,CHO-SEAL® 6370,THERM-A-GAP™ 976,THERM-A-GAP™ 579,WIN-SHIELD™ G,THERM-A-GAP™ GEL 8010,THERM-A-GAP™ HCS10,CHO-SEAL® S6305,DURALAN™ P,CHO-SEAL® 1298,CHO-SEAL® 6502,THERM-A-GAP™ GEL 45,THERM-A-GAP™ G974,THERM-A-FORM™ T646,CHOFORM® 5513,CHO-SHIELD® 2056,THERM-A-FORM™ T647,CHO-SEAL® 6503,PREMIER™ A240-ST,THERM-A-GAP™ TC50,THERM-A-GAP™ 569,PREMIER™ PBT-225,SOFT-SHIELD® 3500,THERM-A-FORM™ 1641,SOFT-SHIELD® 3700
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可定制UV胶的粘度范围:150~25000cps,粘接材料:金属,塑料PCB,玻璃,陶瓷等;固化方式:UV固化;双固化,产品通过ISO9001:2008及ISO14000等认证。
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