Molded Parts - Von Roll

Molded Parts

2 Molded Parts
We Enable Energy
As one of the oldest industrial companies of Switzerland, founded in 1803,
we focus on products and systems for power generation, transmission and
distribution, rotating machines and mechanical engineering. Von Roll is the
global market leader for insulation products and the only company to offer
the complete range of insulation products, composites, consulting, tests
and services for the electrotechnical industry.
For more than 100 years, we have been making outstanding contributions
to this market, developing a number of highly innovative products that have
enabled both steady increases in power output and smaller and more
compact machines.
Customers enjoy the following benefits:
» One single source for all insulating materials
» Thorough expertise from power generation and transmission
to its efficient utilisation
» Proven compatibility for system components
» Testing at Von Roll of both materials and systems
» Consulting for applications and technologies
» Training in insulation materials and systems
Focusing on molded parts, we have been one of the most recommended
experts in tool design, material formulation and processing
for molded parts for decades.
Our long-standing experience with thermoset materials is a real plus in
the field of power distribution, as well as in a variety of applications outside
of electrical engineering. Within our composites range we design, develop
and produce high-performance molded parts, offering:
» Expert advice devising the production concept
» Tool design
» Customized formulation of molding compound
» Creating of future-oriented thermoset moldings to keep pace with
ever-increasing market requirements

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Fields of Application
Von Roll moldings meet the most demanding performance requirements, and their
uses today are not restricted to electrical engineering; they can also be found in the
most diverse range of industrial and everyday appliances:
» Aviation
» Automotive
» Electrical equipment (high- and low-voltage switchgear)
» Industrial equipment (chemical industry, paper industry)
» Medical equipment
» Household equipment
» Oil and gas industry
» Public transport
» Electronics
Range of Services
Von Roll offers the complete range of services, from product planning consultancy right
through to the completed ready-to-install molded part.
Customer
Application
Product initiative
Von Roll
Technical
advice /
Conception
Tool design/
Tool manufacturing
Molding
compound
formulation
Molded
parts
manufacturing
Molded
parts processing Quality testing Packing/boxing Logistics
Competence
Tools
Component / Manufacturing process
Logistics
Consultancy/Design
Right from the development phase, Von Roll offers expert support in the design of the
article that is to be produced. Here a special emphasis is laid on the economic and
press technology aspects. On request we are happy to work with the customer in the
consultancy phase as well as to develop solutions based on value analysis. Such value
analyses are also useful later on for setting targets for cost reduction during serial
production.
To meet the needs of the individual customer’s specific application and in consultation
with the customer, we will draw up a catalogue of specifications for the press tools that
are needed and for the molding material formulas that are best adapted to the required
workpiece properties. While we are able to draw on our experience of design and
manufacture going back to the year 1921, we are also familiar with the latest technological
trends.
This way the services we offer always include all-round support of the intended project
by all specialist divisions within the company.

4 Molded Parts
Tool Design
With our many years of experience of tool development, we can offer the best solution
even for the most complex and demanding design requirements. Depending on the
nature of the task, the use of shim tools or slide tools may be advisable. These will be
designed using CAD technology as part of the component development process.
The tool design will be sent to an external manufacturer in the form of 3D data. Von Roll
accompanies the creation of a new tool from the in-house design right through to the
successful launch of serial manufacturing by our production department and beyond.
CAD tool and part design
Base plate for on-load tap changers
We are also happy to plan and execute the adaptation of third-party tools which may
have been in use for other manufacturing procedures.
Formulation of Molding Materials/Range
With its experience of duroplasts going back to 1912, backed up by continuous
research and development right through to the present, Von Roll has acquired
a comprehensive knowledge of molding materials. It goes without saying that the
selection of a composition for the molding materials will be strictly tailored
to meet the customer’s requirements.
Our range of SMC/BMC moldings and casting resins covers:
» Molded parts made from polyester resins
» Molded parts made from epoxy resins
» Molded parts made from phenolic resins
» Molded parts made from other resin systems
» Supports (insulators and clamping devices)
Glass filaments and glass rovings are primarily used as reinforcement material. But
also carbon, aramide and other materials are used to achieve the given requirements
in the reinforcement.

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The following table shows our product range of molding compounds. The difference
in the receptor designs for the individual application fields gives rise to a classification
for the molding materials:
Cut roving-mat
Kneader
Endles roving
Low-shrinkage
Arc-resistant
Flameresistant
High-grade
smooth surface
High-temperature-resistant
Mechanically
highgrade
Antistatic
Durapreg ® MS • •
Durapreg ® MSF • • •
Durapreg ® MSLF • • • •
Durapreg ® MLF • • •
Durapreg ® KLF • • •
Durapreg ® MSVA • • • •
Durapreg ® MWH • • •
Durapreg ® EW • •
Durapreg ® PF31 Special phenolic resin qualities
Durapreg ® HUP Special qualities for aviation
Durapreg ® Carbon Special qualities with carbon fiber reinforcement
Durapox ® SK60L8 Special epoxy resin qualities
The duroplastics used in these applications are characterized by a high performance
level and possess the following properties:
» Good electrical insulation properties
» High ability to retain shape
» Very high mechanical stability
» Low creep tendency
» Temperature resistance up to 140°C (in special cases up to 180°C)
» Good mechanical stability at temperatures below –60°C (no embrittlement)
» Chemical resistance
» Homogeneous coloring
» Paintable surface
» Resistance to atmospheric conditions and ultraviolet light
» Self-extinguishing when using halogen-free flame protection material up to UL94V-0
for walls with a width of 3.2 mm
» Narrow tolerances
» Lightweight construction for aviation application
» The possibility to modify material to achieve additional properties as required by the
customer

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Properties of molding materials made of glas fiber-reinforced polyester, phenolic and
epoxy resins:
Properties Standard Unit
Durapreg ®
MS
Durapreg ®
MSF/
Durapreg ®
MSLF
Durapreg ®
MLF
Durapreg ®
KLF
Durapreg ®
MSVA
Durapreg ®
MWH
Durapreg ®
EW
Durapreg ®
HUP
Durapreg ®
PF31
Density ISO 1183 A g/cm 3 1.75 1.75 1.8 1.87 1.8 1.8 1.8 1.62 1.4 1.8
Flexural modulus
of elasticity
Durapox ®
SK60L8
ISO 14125 MPa 10 500 10 500 10 000 9 000 11 000 15 000 28 000 8 000 7 000 18 000
Flexural strength ISO 14125 N/mm 2 150 150 150 80 150 210 580 >150 90 195
Impact strength ISO 179 kJ/m 2 70 70 70 >15 80 130 200 >65 8 40
Tensile strength EN 61 MPa 70 70 70 30 70 120 (500) – 60 –
Compressive
strength
Heat deflection
temperature
ISO 604 MPa 150 150 150 120 160 200 200 – 200 –
DIN 53458 °C >200 >200 >200 >200 >200 >200 >200 >200 140 >200
Flame resistance UL 94 Class – V0 / 3 V0 / 4 V0 / 0.8 – – – V0 / 2 V0 / 3 V0 / 3
Tracking resistance IEC 112 CTI 600 600 600 600 – 600 600 – 125 600
Electrical disruptive
strength
Specific volume
resistance
Surface
resistivity
IEC 243.1 kV/cm 100 100 150 160 – – – >100 300 170
IEC 93 Ω cm 10 15 10 15 10 15 10 14 10 5 10 13 – 10 14 10 10 10 15
IEC 93 Ω 10 13 10 13 10 13 10 12 10 5 10 13 10 13 10 13 10 9 10 13
Heat conductivity DIN 53612 W/mK 0.4 0.4 0.4 0.4 – 0.6 0.6 – – 0.5
Linear
expansion
coefficient
VDE 0304 1/K
10 –6 20 20 20 20 17 35 35 – 35 –
Moisture absorption ISO 62 mg/4d

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Depending on their individual technical properties the thermosets are qualified for use in
several of a wide variety of applications.
Applications for molded parts made of SMC*-, BMC**-, phenolic-, carbon-, epoxymolding
compounds:
Molding compound
Durapreg ®
MS
Durapreg ®
MSF
Durapreg ®
MSLF
Durapreg ®
MLF
Durapreg ®
KLF
Durapreg ®
MSVA
Durapreg ®
MWH
Durapreg ®
EW
Durapreg ®
HUP
Durapreg ®
PF31
Durapreg ®
Durapox
Durapreg ®
Carbon
Application
Electrical engineering • • • • • • • • •
Circuit breakers • • •
On-load tap changers • • •
Arc chambers • •
Lamp casing • •
Chemical plant
engineering
Mechanical
engineering
• •
• •
Precision engineering • •
Agriculture
Vehicle construction/
railways
• • • •
•
Aviation • •
*sheet molding compound; **bulk molding compound
Suitability of qualities in certain applications
Pole shell for mid-voltage
switchgear application
Front and rear wall for low-voltage circuit
breakers
Scanner frame for professional film
development

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Low-voltage circuit-breaker in electrical engineering
Control switch for crane systems
Manufacture of Molded Parts
With the help of our extensive and varied machine resources, our manufacturing technology
is well able to replicate the widest range of molded parts. We can also process
auxiliary materials, such as metal.
For individual optimized moldings we use a variety of pressing, transfer molding and
injection molding procedures. Electrically, 180°C hot water or thermal oil heated
and fully automatically controlled presses are used as well as injection molding machines
with a clamping force of 2750 kN.
Process Press group Number Max. table size Max. opening
Presses/transfer molding
presses
1000 up to 2000 kN 11 800 x 800 mm 1000 mm
2000 up to 4000 kN 13 1200 x 1000 mm 1250 mm
6000 up to 16000 kN 5 2000 x 1500 mm 1750 mm
Injection molding several up to 2750 kN 910 x 910 mm 660 mm
With these technical resources we are able to create molded parts ranging in item
weight from 0.1 to over 15 kg.

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CAD tool design
Shop floor
When significant changes are made in the manufacturing process or new molded parts
are introduced, our application technology accompanies the product and the process
right through to documentation of serial maturity based on prototype test reports.
Molded Part Processing
In the course of the subsequent manufacturing process, further mechanical processing,
surface treatment or installation activities may be called for.
Here Von Roll offers a wide range of processing options – anything from manual deburring
to processing on an NC table or use of a 5-axis robot.
Customers can also draw on the resources of our paint spray department and our
assembly stations, which are capable of putting together complete assembly groups.
Products can also be given customized labeling.
Quality Assurance/Testing
In the course of quality control we will carry out all the tests required, based on various
test approaches. With the help of coordinate measurement machines we will execute
the mandatory tests of prototype samples and ensure that manufacturing tolerances
have been adhered to.
Our laboratory analysis makes sure that the molding materials maintain a consistent
standard of quality and demonstrate the required physical properties.
We can also help the customer draft documents for the certification or licensing of
molded parts.
Our quality management system has had ISO 9001 certification since 1997. In addition,
we have an environmental management system in place with ISO 14001 certification.

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Load Collation/Logistics
On request we are happy to take responsibility for load collation and dispatch of the
product (even when the product includes separate accessory parts), extending as far as
the assembly and packaging of complete sales packages.
Transport packaging that is in keeping with the nature of the product and chosen
distribution channel adds the finishing touch to the service we provide.
We deliver on time, from the factory or the warehouse, to destinations all over the world.
Based on our partnership with highly effective logistics firms, we can offer worldwide
delivery at very favorable cost.
Examples of Applications
The following pictures show a selection of products that we have specially developed for
specific customer needs or applications:
Retail security system
Parabolic dish for TV receivers
Pump case/parts for use in chemical
plant engineering
Case part for copier
Explosion-proof lamp housing for use in the
chemical industry, e.g. refineries
Sunroof frame panels for the automotive
industry

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Standoff Insulator and Busbar Supports
In addition to these individual solutions we also offer standardized insulator supports
and clamping devices which are available from our stock for all your construction
and repair needs.
These are made of polyester (UPGF) or epoxy resin (EPGF).
We supply cylindrical or hexagonal supports with metric metal threads (steel and brass),
ranging from 18 mm to 70 mm in height and 15 mm to 80 mm in diameter. These
provide an ideal solution for the insulation of AC operating voltages of up to 3 kV.
Feel free to ask for separate detailed information about this line:
Standoff insulator and busbar supports

We Enable Energy
Von Roll is the sole full-range supplier of materials and systems for the insulation of electrical
machines as well as high-performance products for various high-tech industries.
Mica
Materials related to high-voltage insulation.
Von Roll’s commitment is extensive, including
all the steps in the manufacturing process.
Wires
Insulated round, flat and Litz wires for
high-voltage, low-voltage and electronic
applications.
Cables
Mica tapes for fire-resistant cables. Von Roll
provides a wide range of products that are
ideally suited to all commonly used standards.
Liquids
Impregnation resins for high and low voltage,
potting resins, casting resins, as well as
encapsulating and conformal coatings.
Composites
Engineered materials made from a resin and
a support structure with distinct physical,
thermal and electrical properties. They can
be molded, machined or semi-finished.
Please contact us or visit our website www.vonroll.com for further information:
Europe, Middle East, Africa
Von Roll Holding AG
Steinacherstrasse 101
8804 Au ZH
Schweiz/Switzerland
P +41 44 204 3500
F +41 44 204 3010
Asia/Pacific
Von Roll Asia Pte Ltd.
Blk 6 Serangoon North Avenue 5
Singapore 554910
Singapore
P +65 6556 4788
F +65 6556 4959
Flexibles
Insulating flexible materials for low-voltage
applications such as flexible laminates and
adhesive tapes.
Transformers
High-perfomance transformers for power
transmission and distribution, tailored
solutions to all applications of today’s energy
supply companies.
Testing
Von Roll provides electrical, thermal and
mechanical testing of individual materials as
well as complete insulating systems. We are
UL-certified.
Training
Von Roll Corporate University provides
a training program in high- and low-voltage
insulation to its customers.
Americas
Von Roll USA, Inc.
8480 East Orchard Road
Suite 1000
Greenwood Village, CO 80111
USA
P +1 303-689-8441
F +1 303-689-8458
About Von Roll
As one of the longest established industrial companies in Switzerland, founded in 1803, we focus
on products and systems for power generation, transmission and distribution, rotating machines and
mechanical engineering. Von Roll is the global market leader in insulation products, systems and
services and is represented at more than 32 locations in 19 countries with around 3,400 employees.
Sämtliche Informationen in diesem Dokument unterliegen den Haftungsbedingungen wie sie in der Website www.vonroll.com unter Rechtsinformationen erwähnt sind. Konzept/Design: www.idfx.ch, 03/2009