Eliminating Burning Odor in Connector Fixtures by Switching to PTFE

Background Information

A customer in the connector manufacturing industry had been using Bakelite fixtures in their production process. Over time, operators began noticing a strong burning smell during use. The customer reached out to us for a redesign that could eliminate the odor without compromising fixture accuracy or durability.

Problem Statement

The issue was traced to excessive friction during operation, which caused the Bakelite to overheat beyond its continuous-use temperature. Although Bakelite is a thermosetting resin that doesn’t melt under heat, it can burn when exposed to sustained high temperatures—resulting in the unpleasant odor. In addition to the smell, the fixture surfaces showed signs of wear, raising concerns about precision loss over time.

Solution Implementation

We proposed replacing the Bakelite with PTFE (polytetrafluoroethylene), a high-performance engineering plastic well suited for applications involving friction and heat. PTFE offers excellent heat resistance, low friction, and wear resistance, with a continuous-use temperature of around 260°C (482°F). It is also flame-retardant and self-extinguishing, making it far less prone to burning or deformation. By switching to PTFE, we eliminated the friction-related heating issue and ensured long-term dimensional stability. The new fixtures performed smoothly under the same operating conditions while maintaining precision and preventing odor buildup.

Results

The switch to PTFE completely removed the burning odor and significantly improved fixture durability. The customer was pleased not only with the product quality but also with the proactive material recommendation and technical guidance provided throughout the process.

Customer Feedback:

“Thank you for your thoughtful advice on material selection. Your experience with different plastics really showed. We’re very satisfied with the result.”
(Manufacturing Industry / Hiroshima Prefecture)