Chloe Zhang
Plastic is an integral part of electronic devices, from smartphones to refrigerators, and plays a crucial role in their protection, user-friendliness, and weight reduction. The type of plastic used depends on various factors, including mechanical requirements, insulation needs, thermal performance, and cost. Some commonly used plastics in electronics include ABS, a versatile thermoplastic polymer with excellent impact resistance and heat resistance, and Polycarbonate (PC), known for its transparency, high-impact resistance, and heat resistance. Other plastics like Polyethylene (PE), Polyamide (PA), and Polyethylene Terephthalate (PET) are also widely used for insulation, packaging, and optical applications. Injection molding is a popular manufacturing method for plastic electronic components due to its versatility, customizability, and ability to produce complex shapes. As environmental concerns grow, bioplastics and recycled materials are also being considered for non-critical components.
| Characteristics | Values |
|---|---|
| Role | Protection, enhanced user-friendliness, weight reduction, insulation, fire safety, etc. |
| Common Types | Polyethylene (PE), Polyethylene Terephthalate (PET), Polymethyl Methacrylate (PMMA), Polycarbonate (PC), Polyamide (PA), Acrylonitrile Butadiene Styrene (ABS), Polyimides (PIs), Polybenzimidazole (PBI), etc. |
| Properties | Impact resistance, heat resistance, dimensional stability, transparency, tensile strength, dielectric strength, thermal insulation, electrical insulation, flame resistance, etc. |
| Applications | Cable insulation, wire harnesses, packaging materials, display screens, lenses, structural components, connectors, casings, coatings, adhesives, etc. |
| Advantages | Energy efficiency, recyclability, customizability, lightweight, cost-effectiveness, etc. |
| Disadvantages | Potential toxicity, hazardous emissions, environmental concerns, etc. |
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What You'll Learn
ABS plastic
Acrylonitrile Butadiene Styrene (ABS) plastic is one of the toughest thermoplastic polymers. It is a blend of acrylonitrile, butadiene, and styrene, which gives it a unique set of properties that make it suitable for a wide range of applications. ABS plastic is known for its impact resistance, versatility, and electrical insulation properties, making it a popular choice for consumer electronics.
One of the key advantages of ABS plastic is its impact resistance. This makes it ideal for applications that require toughness and the ability to withstand extreme shock values. For example, in the automotive industry, ABS is used for both interior and exterior components such as dashboards, door panels, and mirror housings. ABS plastic's strength and impact resistance also make it a popular choice for toys and games, as it can be moulded into intricate shapes while remaining durable.
Another important property of ABS plastic is its electrical insulation capability. This makes it suitable for use in electrical and electronic components, housings, and enclosures. ABS plastic is also FDA-approved for food-related applications since it resists chemical-induced corrosion. Furthermore, ABS plastic is highly recyclable and can be melted down and altered as desired, making it a cost-effective and environmentally friendly choice.
However, ABS plastic does have some limitations. It has poor weather resistance and is susceptible to degradation when exposed to sunlight and UV radiation. It can become brittle and discoloured over time, limiting its outdoor applications. ABS plastic is also classified as a combustible material with low resistance to fire, and it may deform or lose its mechanical properties at higher temperatures. Despite these drawbacks, ABS plastic remains a popular choice for many applications due to its unique combination of strength, versatility, and cost-effectiveness.
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Polycarbonate
In the electronics industry, polycarbonate is crucial in consumer electronics, industrial automation, and household appliances. It is used in electrical enclosures to protect sensitive devices and equipment from external factors while ensuring strong signal transparency.
To address the global plastic waste crisis, companies are developing sustainable solutions, such as the introduction of post-consumer recycled (PCR) polycarbonate. This recycled polycarbonate aims to reduce the reliance on fossil-based resources and extend the lifecycles of electronic devices.
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Polyamide
In the electronics industry, polyamide is used in phones and computer motherboards. It is also used in gears, bearings, and other mechanical components. Nylon, a type of polyamide, is commonly used for injection moulding and 3D printing applications.
Despite its advantages, polyamide has some limitations. It has a tendency to absorb a lot of water, and many types degrade quickly when exposed to UV radiation or light.
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Polyethylene
The commercial production of polyethylene began with the development of catalysts that promoted polymerization at mild temperatures and pressures. The first of these was a catalyst based on chromium trioxide, discovered in 1951. In 1953, a catalytic system based on titanium halides and organoaluminium compounds was developed, which worked at even milder conditions. By the end of the 1950s, both methods were being used for HDPE production. Over time, these systems were improved and incorporated into other catalytic systems.
When selecting plastics for electronic applications, it is important to consider a multi-criteria decision-making approach. Factors to consider include mechanical, thermal, and electrical properties. Environmental concerns are also growing, and recycled materials or bioplastics should be considered for non-critical components.
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Polymethyl Methacrylate
PMMA is a popular alternative to glass due to its transparency, rigidity, and shatter-resistance. It is lightweight, durable, and offers superior clarity, making it suitable for a wide range of applications. These include aquariums, automotive light lenses, aircraft canopies, skylights, illuminated signs, optical fibres, and more.
PMMA is manufactured using propylene, which is refined from crude oil. The process involves reacting propylene and benzene to form cumene, which is then oxidized to create cumene hydroperoxide. After treatment with acid, it becomes acetone, which is then converted into methyl methacrylate through a three-step process. The final step involves polymerizing methyl methacrylate to form solid PMMA.
PMMA has a glass transition temperature (Tg) ranging from 85 to 165 °C for commercial grades. It is an organic glass at room temperature and can be formed using various molding processes, including injection molding, compression molding, and extrusion. The highest-quality PMMA sheets are produced by cell casting, resulting in higher strength than molding grades.
PMMA is a versatile material with numerous applications. It can be used in its pure form or modified with additives and fillers to enhance specific properties for particular applications. For instance, comonomers can be added to improve impact strength, increase glass transition temperature, or stabilize the polymer during processing.
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Frequently asked questions
Polycarbonate (PC), Acrylonitrile Butadiene Styrene (ABS), and Polymethyl Methacrylate (acrylic) are some of the most commonly used plastics for electronic enclosures.
A blend of PS and PPO is good for electronics that need sturdy and resistant housings, such as relays or transformers.
SEBS is an excellent option for plastic electronic enclosures for handheld cases as it is comfortable to the touch.
Some attributes to consider when choosing plastic for electrical needs include UV resistance, chemical resistance, temperature tolerance, flame resistance, colour-ability, transparency, moisture resistance, impact resistance, and stress resistance.
Plastics are used in electrical and electronic applications because they are energy-efficient, recyclable, safe, and hygienic. They are also poor conductors of heat and electricity.
