It is no accident that industrial laminates have been around for as long as they have – which is now almost 100 years.
Laminate comes in a wide range of sizes, thicknesses and grades and enjoys a solid track record of being supplied to, and used by, varied manufacturers around the globe. Those who are responsible for selecting laminates for use in a myriad of different applications have much to consider. Such elements include maximum working temperatures, the mechanical strength, its toughness and impact strength and its machinability to name but a few. Combined together these are all vital to ensuring the overall reliability of the product and the avoidance of any kind of failure.
There are many types and grades of industrial laminates and each manufacturer will have its own recipe for its own individual products. When a product has been found that works well in the particular application while delivering a good result, it is important that the very same product manufactured to the same formula is purchased each time. This way it is possible to ensure consistency and ultimately, reliability for the process and end result.
It is widely recognised in manufacturing that during the last 10 years since the financial crisis and the subsequent recession, procurement departments have inevitably been under pressure to source materials that will do the same job and deliver the same result, but at less cost. In reality, this is something that is virtually impossible to deliver because as the old saying goes - ‘you get what you pay for in life’. With any mechanical component or material, if something is cheaper then it is cheaper for a reason. We have all purchased products in the past that look the same as the more expensive version that we were previously pleased with, only to find it that doesn’t perform as expected and then feel let down.
Quality and reliability
In any manufacturing situation, reliability is key. Aside from the actual process, it is important to use materials that are of the right quality to meet the requirements and expectations of the job.
As with most products, ‘me toos’ are something that can be found in laminates and composite materials and anyone searching for these items online will be faced with an array of products which claim to be ‘equivalent’. The main worry here is that, while it may be possible to take a reasonable ‘stab’ at the recipe, make-up or processes used to create a similar product, it cannot possibly be exactly the same nor deliver the same end result. These factors should be taken into account when sourcing any type of materials, be they laminates or otherwise.
Reliability will inevitably be the price paid for using inferior or ‘copy-cat’ products. Failure during a process which will in turn result in downtime for the equipment and costly loss of production. This underlines the argument that it is wise to turn to the OEM each time in order to ensure consistency and reliability.
Some of the problems which can arise from cheaper products include the level of mechanical strength, the electrical strength and in-service temperature. Because of this, proper and in-depth product testing is key to guaranteeing reliability and creating confidence for the customer.
In the case of Tufnol, we have our own in-house laboratory where products are developed and continuously tested. Working with a manufacturer-supplier with such facilities is always advisable.
Mechanical strength is one area where an inferior material will often fail. This is due to delamination of the layers which can have a catastrophic impact resulting in manufacturing shut downs, leading to expensive loss of production and necessity for repair. Another area where failure can occur is with resistance to surface tracking. In such cases, electrical current will always seek the shortest path and the ability to resist surface tracking is measured and referred to as its Comparative Tracking Index (CTI).
Top performing resins
An example of this is provided by one of Tufnol Composites’ high-performance resin systems which has been modified to give the superior epoxy cotton Grade 6F/45 a CTI of 800. Inferior materials which claim to be an equivalent can only achieve, at best, a figure that is only 75% of this value. Here, it is possible to see that the consequential difference in performance is vast.
It is also important to note that while a product may be manufactured to meet the British Standard, this does not mean that it is necessarily equivalent to the OEM product. This is because products may very well fall within the standard, but it does not make them the same or guarantee the same reliability.
When looking to purchase a reliable product, it is advisable to go to a manufacturer that has experience and enjoys a good reputation. Have a look at the other customers they work with and check out their track record, including which quality assurances they have in place. If they enjoy good relationships with their existing customers, then there is a good chance they will be able to do the same with new customers too.
Close examination of the material specification of the laminate, and consideration of how it will perform to meet expectations, is vitally important.
Leading manufacturers will always try to exceed, rather than simply meet, the British or ISO standard. Those with true technical creativity will be able to achieve this in the same ways that designers of equipment do. Customers can be confident in the service and product they receive and be assured of excellent in-service performance and total material reliability.
When sourcing a new component or material for a specific application, look for an OEM with the right level of knowledge and experience that is willing to give advice on the best solution. This will help to ensure the best and most reliable result in the long run.
