Tag Archives: Industrial Materials

Common Applications for Engineered Thermoplastic Mechanical Components

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Engineered thermoplastics have become increasingly useful in mechanical applications where traditional materials such as metal may not provide the ideal combination of weight, durability, chemical resistance, and design flexibility. Engineered thermoplastics are designed to provide enhanced mechanical and thermal properties. This makes them suitable for demanding components that must perform reliably under stress. They also used to manufacture components such as specialty seals, which need materials that can withstand challenging operating conditions while maintaining reliable performance.

These materials are used in a wide range of mechanical applications, from automotive systems to industrial machinery. Here is a list of common uses for engineered thermoplastic mechanical components.

Common Applications for Engineered Thermoplastic Mechanical Components

Automotive Components

This is one of the largest users of engineered thermoplastics. Manufacturers use them to produce components that need to be lightweight while withstanding heat, vibration, chemicals, and repeated mechanical stress.

They can be used for gears, bushings, bearings, clips, housings, brackets, and various under-the-hood components. Replacing certain metal parts with engineered thermoplastics can reduce vehicle weight, improving fuel efficiency or electric vehicle range.

Industrial Machinery

In industrial settings, machines operate under demanding conditions and depend on components that deliver reliable performance during extended operations and challenging environments. Engineered thermoplastics can be used for gears, rollers, wear strips, guide components, bearing cages, pulleys, and machine housings.

They perform well even in environments exposed to moisture, chemicals, or frequent movement because they resist abrasion and corrosion. Depending on the specific material, thermoplastic components can also operate with relatively low friction, helping reduce wear between moving parts.

Electrical and Electronic Equipment

Engineered thermoplastics are widely used in electrical and electronic applications because they can safely insulate electrical parts, maintain their shape, and remain strong and stable even when exposed to heat or regular use.

Mechanical components may include connectors, terminal housings, switches, brackets, cable management components, and protective enclosures. Materials can be selected based on requirements such as temperature resistance, impact strength, flame resistance, and electrical performance.

Thermoplastics can also be molded into detailed shapes and compact components, which is particularly beneficial today as electronic equipment has become smaller and more complex.

Pumps, Valves, and Fluid-Handling Equipment

Components of pumps, valves, and other fluid-handling equipment are often exposed to water, oils, solvents, chemicals, and other fluids. Certain engineered thermoplastics offer excellent chemical resistance, making them ideal for components that would otherwise be vulnerable to corrosion.

Impellers, valve components, seals, bushings, and pump parts may be manufactured from specialized thermoplastic materials. However, selecting the right grade is essential because chemical compatibility varies by material and operating environment.

Food Processing Equipment

Some engineered thermoplastics suit components in food processing and packaging machinery. These components may include wear guides, bearings, rollers, bushings, and conveyor components.

Manufacturers of food processing equipment may prioritize low friction, resistance to cleaning chemicals, dimensional stability, and ease of maintenance. Choosing appropriate materials is crucial to ensure components meet food-contact or food-processing environment requirements.

Aerospace and Transportation

Strong, reliable, and lightweight mechanical parts are needed in the aerospace and transportation industry. They must also withstand temperature changes, vibrations, impacts, and heavy loads.

Specialized engineered thermoplastics can be used for brackets, clips, bushings, cable-management components, interior hardware, and other structural or mechanical parts. Their strength and relatively low weight make them useful for designers looking for alternatives to heavier materials.

Consumer and Commercial Equipment

Everyday products and commercial equipment also use engineered thermoplastics. Thermoplastic materials can be molded into gears, handles, housings, rollers, adjustment mechanisms, and other mechanical parts.

Choosing the Right Material

Material selection should be based on the specific demands of the application. Temperature, load, friction, wear, chemical exposure, dimensional requirements, and manufacturing method are all factors that need to be considered.

The right materials and design give a practical combination of performance, durability, and manufacturing efficiency.

Get the Right Solution for Your Application

If you need durable, lightweight solutions for your next project, engineered thermoplastic mechanical components can deliver the strength, reliability, and performance demanding applications require. Talk to our experts today to discuss your needs and discover the right engineered thermoplastic solution for your application.

Backup O-Rings

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The Benefits of a Backup Ring

No matter what type of application you have or who you work for, having a system that will run well for as long as possible should be one of your top concerns.

A backup ring is just one of the many little things you can do to help keep your system running smoothly for as long as possible, along with these other methods. But you might be wondering, just how does it work?  There are a few ways a backup ring could improve your system performance and longevity.

Extrusion

O-Rings experience a lot of stress, causing them to wear down in various ways. One of the biggest causes of an O-Ring failure is extrusion, particularly in hydraulic rod and piston seals. Extrusion occurs when the internal pressure of an application becomes too great, causing the O-Ring to extrude – or stick out – into the clearance gap. This extruded or extended portion of the O-Ring will wear down quickly, reducing the amount of material in the O-Ring. After a short period, extrusion results in seal failure.

According to Daemar, some of the common causes of extrusion include:

  • Excessive clearances.
  • Pressure exceeding system design.
  • An O-Ring with an insufficient durometer for the application.
  • Degradation of the O-ring due to system fluid.
  • Irregular clearance gaps caused by eccentricity.
  • Increased clearance gaps due to excessive system pressure.
  • Improper machining of O-ring gland.
  • Wrong O-ring size installed, resulting in an excessively filled groove.

You should inspect your O-rings for signs of extrusion. Examine the edges of your O-rings on the low pressure or downstream side to see if it appears chewed or chipped. If extrusion has caused your O-ring to fail, you should see small pieces missing from the low pressure or downstream side. In some cases, 50% of the O-ring may have been lost already before the leakage has been found.

Preventing Extrusion

There are three ways to combat extrusion. The first is to reduce the clearances in order to lower the extrusion gap. Unfortunately, this is not practical due to the high expenses involved.

It would be much cheaper to instead raise the durometer of the O-ring. An O-ring with a higher durometer would have a much higher resistance to extrusion, but would also bring two other problems with it: namely, the limited availability of higher durometer materials, and that these materials are not as effective in low pressure applications.

Backup Ring

This brings us to the third option: backup rings. Rather than acting as a replacement for your installed O-rings (as its name suggests), a backup ring is actually meant to work in tandem with the O-Rings you have already installed. Backup rings are typically made of materials with high durometers and resistance to extrusion, including nitrile, Viton (FFKM), or PTFE.

The backup ring is installed between the O-ring and the extrusion gap. The addition of a backup ring will improve the pressure resistance of the O-ring, and prevent it from being forced into the clearance gap, reducing the chances of extrusion and premature seal failure. Depending on the direction of the pressure, you may even be able to install two backup rings. This will provide added protection against extrusion and O-ring failure.

Choosing a Backup Ring

You will have a number of options to choose from to cater an O-ring for your application. They come in two styles: a flat, washer-like style, or a contoured face which provides greater grip and support on the O-ring.

They may also have a solid or spiraled construction. A spiraled construction is made of overlapping rings, providing several different contact levels against the shaft. They provide greater support over solid construction backup rings.

Buy Your Backup Rings From an Industry Leader

From humble beginnings as an O-ring distributor in 1970, Real Seal has grown to become a full-service O-ring supplier and industry leader. Real Seal is not only one of the most technologically advanced O-ring suppliers today; we are also one of the few organizations with a fully-equipped laboratory as well as a full-time chemist and technical staff. This allows Real Seal to meet design challenges special material formulations in a way that no other company can. Don’t wait: give us a call and we’ll provide you with backup rings made to your exact specifications as soon as possible.