Real-World Solutions:

3M Thermal Interface Tapes Help to Improve The Life of a LED Lighting Application

Customer Challenge An LED lighting manufacturer came to us seeking ways to improve the lifetime performance of LED bulbs within...

Switching To A More Cost Effective Material, While Maintaining Optimum Performance

Customer Challenge This electronics manufacturer was using a silicone interface pad on a heat sink for a small electronics application....

Utilizing a Sealing Gasket to Keep Unwanted Evironmental Debris From Damaging a Telecommunications Cabinet

Customer Challenge This company was seeking a product for their telecommunications cabinets. These cabinets are built in two separate sections,...

Helping to Create Cost Effective Solutions to an Existing Product Line in the Appliance Industry

Customer Challenge This appliance manufacturing company came to us having already known exactly what they needed from us. It was...

Preventing Hairline Cracks from Forming When Assembling Metal and Plexiglas

Customer Challenge One of our customers making aftermarket parts for a motorcycle manufacturer was having difficulties with a windshield application...

Athletic Equipment Manufacturer Seeks to Improve High-Performance Shin Guards

Customer Challenge An athletic equipment manufacturing company was developing an ultra high-performance shin guard for their line of soccer equipment....

Eliminating the Need for Mechanical Fasteners in an Automotive Application

Customer Challenge A customer in the automotive industry came to us looking for a solution to eliminate the use of...

Sealing Out the Weather Using Microcellular Urethane Foam

Customer Challenge A heating and air conditioning company came to us in search of a more ef cient gasket to...

High Temperature Gaskets For a High Temperature Application in the Fire and Life Safety Industry

Customer Challenge One of our customers who manufacturers fire and life safety devices was in need of a high-performance gasket...

Solving An Electrical Arcing Issue Using Flexible Electrical Insulation Material

Customer Challenge A customer of ours that is an OEM providing controls in the commercial building industry had an application...

Customer Challenge

An LED lighting manufacturer came to us seeking ways to improve the lifetime performance of LED bulbs within their fixtures.

This company was previously using a thermal grease to help transfer the heat being created from the bulbs away from the enclosure.

The problem with using a thermal grease is that it can get quite messy, and unless you are used to working with thermal grease, it is hard to apply and evenly distribute.

SRP Solution

SRP recommended a thermal interface material to dissipate the heat in the fixture. This material is designed to provide a heat transfer path between heat generating components and cooling devices.

We also suggested a microcellular urethane to prevent environmental contaminants from entering the product. We were con dent this was the perfect solution to prolong the life of the LED bulbs.

Results

Our customer was pleased that their thermal-management product was now higher performing and superior to its predecessor. The elimination of the thermal grease resulted in a much simplified assembly process as well.

These cost saving improvements reduced assembly time immensely, while providing more ef cient distribution of heat throughout the application.

 

Equipment Used: Laminating | Flat Bed Die Cutting

Materials Used: 3M™ Thermal Interface Transfer Tape 8810 | Rogers PORON®

Customer Challenge

This electronics manufacturer was using a silicone interface pad on a heat sink for a small electronics application. The purpose of the interface pad is to provide a preferential heat transfer path between heat generating components to keep the product from overheating, which will eventually damage the product and rendering it useless.

The challenge, however, was not in the functionality of the product, but in the expenditure of the application. Our customer was looking to be more cost effective with their products.

SRP Solution

After understanding the temperature specifications of the application, SRP realized that the performance of the silicone adhesive they were currently using was a lot more than what was required.

Our solution was to switch to the 3M™ 5571 Acrylic Thermal Interface Pad to be more cost effective, while continuing to maintain the same performance of the Silicone Pad.

Results

After thorough testing of the new 3M™ 5571 Acrylic Thermal pads, our customer found that this material was more than enough performance to keep their products safe from the heat at a fraction of what they were spending with the silicone interface material.

Equipment Used: Rotary Die-Cutting  Materials Used: 3M 5571 Thermally Conductive Acrylic Interface Pad

Customer Challenge

This company was seeking a product for their telecommunications cabinets. These cabinets are built in two separate sections, and then the sections are pieced together at the end of assembly to form one enclosure.

For this, they needed a gasket that would create a seal between the two sections that wouldn’t affect the integrity of the cabinet.

SRP Solution

Closed cell sponge rubber with a rubber-based adhesive was the perfect candidate for this application for multiple reasons.

Since the application was non-critical, the material did not require specific properties other than seal- ing out water, rain, and dust. Also, considering the seal will never have to be broken, compression set was a non-factor.

Results

A sponge sealing gasket is all that was needed to protect the cabinets from the outside environment. Simple solution to a pesky issue. The combination of materials, coupled with our manufacturing process, allowed us to offer them the highest performing, lowest cost solution.

Equipment Used: Lamination | Automatic Log Slitting  Materials Used: Closed Cell Sponge Rubber + Rubber Based Adhesive

Customer Challenge

This appliance manufacturing company came to us having already known exactly what they needed from us. It was a lightweight, heat resistant gasket using a common thermal material to create a barrier within the oven door of their products.

This particular application really wasn’t a challenge at all. The work was already done for us. However, we are always looking out in the best interest of our customers. Whenever we can offer a suggestion as to how to make their parts higher performing or more cost effective, we will not hesitate.

SRP Solution

Due to our continuing education with 3M, and being up to date on all the latest and greatest solutions on the market, we proposed switching from the insulation paper they had spec’d in to 3M’s new-to-market FRB Series insulation paper.

The 3M™ Flame Barrier FRB Series is flexible insulation for OEM electrical flame barrier applications. The FRB Series products are made primarily of inorganic materials that are intrinsically flame retardant with good dielectric strength.

Results

Not only did it meet every stringent need for their application, but also it came with a 23% lower cost solution for them without sacri cing performance with the potential for a better end product.

Equipment Used: Flatbed Punch Press/Steel Rule Die  Materials Used: 3M™ FRB Series NT-15 + 3M™ 467MP Adhesive

Customer Challenge

One of our customers making aftermarket parts for a motorcycle manufacturer was having difficulties with a windshield application during their assembly process.

When assembling the base of the windshield to metal brackets on the motorcycles, it was creating hairline cracks in the Plexiglas®.

This was obviously a major quality issue, especially when the business model of the company they are selling to maintains the highest quality assurance.

SRP Solution

As convertors, we understand that when two objects or parts are being put together, there usually needs to be a separation such as a gasket to aid in the force or tension being created.

SRP recommended separating the steel and Plexiglas® with a microcellular urethane gasket to prevent cracks from being created in the Plexiglas®.

Results

Due to the simplicity of the part, it was an extremely cost effective solution that worked wonders for their product.

The part also provided seamless integration in the assembly process, and the change was virtually unnoticeable due to the thickness of the microcellular urethane.

Since this material does not take a compression set, the product will last for the duration of the final product.

Equipment Used: Rotary Die Cutter | Flash Cutter  Materials Used: Rogers PORON®

Customer Challenge

An athletic equipment manufacturing company was developing an ultra high-performance shin guard for their line of soccer equipment.

In order to manufacture the highest performing sports equipment on the market, they started with an aerospace grade 100% Carbon Fiber Composite material for their shin guards.

To complete the product, padding needed to be added for comfortability, and to protect the player from getting hurt or injured.

SRP Solution

For the padding, a lightweight, high-performance material was necessary. Our customer selected Rogers PORON® XRD® with Microban® to be adhered to the back of the shin guards.

PORON® materials are ideal for applications where compression set resistance is a key product feature. This feature allowed our part to last throughout the lifetime of the product without any degredation.

Results

SRP’s manufacturing expertise enabled us to produce a custom-shaped pad using PORON® XRD® Extreme Impact Protection urethane foam as a cost-effective solution.

An additional benefit of using this material over conventional foams is it’s infusion with Microban® Antimicrobial Technology to help prevent the growth of bacteria that causes stains and odors.

Equipment Used: Pressure Sensitive Adhesive Laminator | Flash Cutter  Materials Used: 2MM THK PORON® XRD® with Microban® technology  |  3M™ 9472 Pressure-Sensitive Adhesive