What is phenolic material, what are its types and uses

Phenolic resin is an industrial Electrical Laminates that has numerous applications and formulations depending on its material and specific properties. It is widely used in electronics manufacturing and part production. Atlas Fiber offers a variety of phenolic materials, including glass, canvas, linen, and paper. Discover more about the numerous uses and advantages of phenolic composites.

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1. What is phenolic material?

Phenolic materials are composite substances created when layers of fabric are coated with phenolic resin, heated, and placed under high pressure. This resin consists of formaldehyde and phenol, which bond to form large molecules. Phenolic materials, a type of resin composite based on phenol and aldehyde, are typically produced by polymerizing phenol and aldehyde monomers in the presence of a catalyst. They are recognized for their high strength, excellent heat resistance, electrical properties, and chemical stability.

What type of plastic is phenolic?

Often referred to as the first plastic, phenolic resin is akin to bakelite. It was the first commercially successful synthetic resin derived from phenolic compounds. As a thermoset plastic, once the material is formed through heating and cooling, its structure remains fixed.

Phenolic material classification

Phenolic materials can be generally divided into two primary categories: phenolic encapsulation materials and phenolic composite materials.

Phenolic packaging materials: This category is primarily used in electronic packaging, including the manufacturing of electronic components, circuit boards, and insulators. Phenolic encapsulating materials have outstanding electrical insulation properties, strong moisture resistance, and good high-temperature performance, making them popular in the electronics industry.

Phenolic composite materials: These are typically composite materials made from phenolic resin combined with reinforcing agents (like fiberglass, paper, or mica). Such composites are excellent for producing wear-resistant parts, mechanical components, and insulating materials.

2. Types of phenolic composite materials

There are three main types of phenolic composites: paper-based, cloth-based, and glass-based. Each type has distinct properties and applications.

Paper-based phenolic resin: This type consists of a resin binder and a kraft paper base material. It features good electrical insulation and mechanical properties, usually at a lower cost compared to other phenolic types.

Cloth-based phenolic resin: Typically made from resin combined with linen or cotton canvas, each option presents its own pros and cons. Canvas phenolic generally has higher mechanical strength than linen, but linen is easier to machine. Both cloth types can be designed to enhance electrical properties.

Glass-based phenolic resin: This variety possesses the best mechanical strength, heat resistance, and electrical properties of all phenolic materials.

Phenolic cotton fabric laminate sheet phenolic cotton board

3. What is phenolic plastic used for?

The applications of phenolic composites depend on the material type. G-3, or glass phenolic, is ideal for applications requiring low thermal expansion and high heat resistance. Due to its corrosion resistance, it is often used to produce acid-resistant components. Some applications of glass phenolic resin include:

• Seal
• Gasket
• Oven parts
• Structural applications
• Relay

Paper-based phenolic composites are better suited for applications that do not require high heat resistance, such as:

• Obstacle
• Duote Product Page
• Switchboard
• Terminal block
• Washer

4. Phenolic Resin Cost Comparison

Phenolic resin countertops offer substantial value and versatility, fitting into various budgets as they are typically mid-priced compared to alternative materials.

In comparison to epoxy resin, often used in laboratory settings, phenolic resin delivers around 90% of the benefits at a significantly lower cost. While epoxy resin countertops can range from $100 to $200 per square foot, phenolic resin averages between $15 and $18 per square foot, with prices increasing based on specific modifications.

Moreover, phenolic resin is often more readily available, reducing lead times, which is crucial for labs where time sensitivity is paramount. With fewer manufacturers of epoxy resin available, projects requiring epoxy might encounter longer lead times than those using phenolic resin.