Lightweight Ceramic Solutions for Large Electrical Projects

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Discussion Overview

The discussion revolves around finding lightweight ceramic alternatives suitable for large electrical projects, focusing on materials that maintain the properties of ceramics such as electrical insulation and temperature resistance while being significantly lighter. Participants explore various materials, including plastics and composites, and their suitability for the intended application.

Discussion Character

  • Exploratory
  • Technical explanation
  • Debate/contested
  • Experimental/applied

Main Points Raised

  • One participant seeks a lightweight ceramic alternative that retains properties like electrical isolation and temperature insulation.
  • Another suggests carbon fiber but notes its conductivity, which does not meet the insulation requirement.
  • A participant proposes aerogel and glass microsphere-filled ceramics, questioning their heat tolerance and suggesting potential trade-offs in compressive strength.
  • Several plastics are mentioned, including Lexan, Ultem, and others, with concerns about deformation before melting.
  • A thermoset polymer like Bakelite is suggested as a potential alternative, though concerns about its toxicity during machining are raised.
  • One participant inquires about sourcing chemicals for Bakelite and seeks more detailed information about its properties and comparisons to fiberglass.

Areas of Agreement / Disagreement

Participants express differing opinions on the suitability of various materials, with no consensus on a single best alternative. The discussion remains unresolved regarding the optimal lightweight material for the specified application.

Contextual Notes

Participants mention specific temperature ranges and mechanical properties but do not provide definitive conclusions about the performance of the suggested materials under the project's conditions. There are also references to deformation issues with certain plastics that may affect their usability.

Arctic Fox
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I need ceramic for a very large electrical project. The problem I have is weight. I would like to find a material with all the properties of ceramic (electrical isolation, temperature insulation, armourment, ability to design for any shape), but it needs to be a lot lighter.

I thought there might be some types of plactics or fiberglas that I could use, but I've no idea.

Price won't be a problem. The material is needed. Anyone with ideas?
 
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Carbon Fiber

JMD
 
Last time I checked, CF was an electrical conductor not an insulator.

CF's got some great properties - some that exceed ceramic. But, insulation is my primary need. :)
 
Aerogel if it can take the heat.

How about a glass microsphere filled ceramic? It might lose a little compressive strength along with its weight loss but should otherwise retain electrical and thermal properties.

What temperature range are we talking about? I believe some of the Ren plastics can handle injection molding stress and temps. They list a casting resin here that goes to 408F for a 264psi deflection test:
http://www.freemansupply.com/tables/renepoxycasting.htm
And here's a laminating resin that's listed as 460F:
http://www.freemansupply.com/tables/renepoxylam.htm

Cliff
 
I remember testing the optical properties of some plastics that were supposed to have good thermal and mechanical properties. They were:

Lexan - reinforced with glass fibers
Ultem - as above
Acrylonitrile Butadiene Styrene
Polyetheretherketone
Duron

Some of them had deformation issues. They would deform long before melting.

Njorl
 
Njorl said:
I remember testing the optical properties of some plastics that were supposed to have good thermal and mechanical properties. They were:

Lexan - reinforced with glass fibers
Ultem - as above
Acrylonitrile Butadiene Styrene
Polyetheretherketone
Duron

Some of them had deformation issues. They would deform long before melting.

Njorl

Then perhaps a thermoset, rather than a thermoplastic polymer would be in order. Something like Bakelite?
 
Bakelite is very useful, but very toxic when you machine it. Be careful. I used it for a device once. I was lucky, I just drew up what I wanted and told some pros to make it.

Njorl
 
Where can I find chemicals for Bakelite? From what I've searched, it seems to be somewhat like fiberglas? I haven't found any detailed information about it - links anyone?
 

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