Material choosing for voltage controller

 High density polyethylene (HDPE) is one of the most used thermoplastic, due to its high availability,
low cost and superior processing property.
it is high strength to density ratio making I t is good dielectric property so it used as electronic
materials.

 ABS is a thermoplastic polymer that is obtained through a process called polymerization, which involves
combining of three monomers: Acrylonitrile, Butadiene, and Styrene (ABS)
 The selection of the type of material is depends on the specific requirements of the final product, including
its flexibility, durability, mechanical property, electrical property and temperature resistance.

S.N Property Material type Aveg Material type Aveg Additional description
ABS
HDPE
1 Physical property
-Density 0.924-0.99.5g/cm3 0.9545g/cm3 0.882-3.5g/cm3 1.075g/cm3
-Melt flow 0.025-1610g/10min 22.9g/10min 0.08-125g/10min 16.6g/10min
2 Mechanical
property
-Tensile strength 7.60-43.1Mpa 21.9Mpa 2.60-73.1Mpa 40.9Mpa
ultimate
-Elongation @break 1.4-230% 58% 1.4-110% 28.6%
Modulus of 0.565-1.5Gpa 0.995Gpa 0.778-21.2Gpa 2.35 Gpa
elasticity
3 Electrical property
-Electrical 1e+1.00e+17ohm- 1.87e+16ohm- 1500.1.00e+18ohm 1.87e+16ohm-cm
 Resistivity cm cm
-surface resistance 10000- 3.36 +13ohm 1000- 6.89e+15ohm
1.00e+14ohm 2.000e+17ohm
-Dielectric constant 2.1-3% 2.41 2.7-3.8% 2.98
-Dielectric strength 19.7-150.7KV/mm 60.5KV/mm 15.7-53.0KV/mm 32.0KV/mm
4 Thermal property
-Thermal 0.288-0.480 W/mk 0.396 W/mk 0.28-0.187W/mk 0.162 W/mk
conductivity
-Maximum service - 70-120℃ 96.7℃ 50-109℃ 74.9℃
Temperature Air
5 Process property
Process Temp 82.2-280℃ 114℃ 170-270℃ 212℃
Nozzle 160-275℃ 241℃ 180-310℃ 238℃
Melt Temp 130-280℃ 221℃ 149-323℃ 234℃
Mold Temp 5-65.6℃ 23.2℃ 10-120℃ 62.3℃
Injection Velocity 200-240mm/sec 232/mm/sec 200-240mm/sec 232/mm/sec
Drying Temp 108--120℃ 12084.2℃ 60-120℃ 12084.2℃
Impact strength 31kj/m2 39.7kj/m2
Injection pressure 2.76-103Mpa 26.5Mpa 4.14-130Mpa 58Mpa

Properties of Thermoplastic Materials: Have a significant impact on their applications. For example, high tensile strength materials are
used for rigid products, while materials with high elongation at break are used for products that require flexibility
Therefore, using the above table ABS and HDPE of property comparing and select the best materials for voltage controller covering (low
voltage enclosure)
Electrical property;- Even if thermal conductivity of HDPE is high than ABS. HDPE has high Dielectric strength than ABS. ,
Thermal property: - HDPE has relatively Low melting Temp compared to ABS this low melting point makes easily process injection
molding techniques .It has high thermal conductivity(poor conductor of heat) relatives to ABS and HDPE can operating in high temperature
than ABS.
Physical and process property:- at the above seen in the table tensile strength of HDPE is enough for the purpose of covering of voltage
controller It has high elongation@ break which provide the flexibility products, the melting temp is low than ABS, the density of HDPE is
high but the product is small type product is produce so, it is not mandatory . It is excellent impact resistance which making it high durable
and capable of withstanding sudden impact its absorb and disperses energy effectively preventing breakages.
Therefore, HDPE is selected materials for covering of voltage controller; the electrical insulting strength is usually measured with the
help of dielectric strength mechanical and thermal strength and also HDPE available in low cost .

Remark
For making mold design use the process property in the table