Differences between Thermoset Coils, Thermoplastic Coils, and Hydraulic Coils

 Thermoset coils, thermoplastic coils, and hydraulic coils are three common types of electromagnetic coils. The key differences lie in material types, application scenarios, and performance characteristics. Below is a detailed comparison of their structure, performance, manufacturing processes, and applicable fields.


Hydraulic coils


1. Concepts and Definitions


Type

Definition

Thermoset Coil

The coil housing is made of thermoset materials (e.g., epoxy, phenolic resin), which cannot be reshaped once cured.

Thermoplastic Coil

The coil housing is made of thermoplastic materials (e.g., PA66, PBT), which can be repeatedly heated and reshaped.

Hydraulic Coil

Specifically designed for hydraulic system solenoid valves, with features like high pressure resistance, oil resistance, and corrosion resistance.


 

2. Material Differences


Coil Type

Main Material

Characteristics

Thermoset Coil

Epoxy resin, phenolic resin, DMC, BMC

High heat resistance, chemical resistance, and dimensional stability, but low toughness.

Thermoplastic Coil

PA66, PBT, PC, PEEK

High toughness, easy to process, suitable for mass production.

Hydraulic Coil

Typically thermoplastic housing with special sealing treatment

Excellent high-temperature, high-pressure, oil, and water resistance.


3. Performance Comparison


Performance Indicator

Thermoset Coil

Thermoplastic Coil

Hydraulic Coil

Heat Resistance

✅ Excellent (200°C and above)

❌ Good (100°C to 150°C)

✅ Excellent (suitable for high-temp environments)

Corrosion Resistance

✅ Excellent

❌ Moderate

✅ Excellent (suitable for oil and corrosive environments)

Water Resistance

✅ Excellent (can achieve IP67)

✅ Good, but requires additional sealing

✅ Excellent (designed for harsh environments)

Mechanical Strength

❌ Low toughness, prone to cracking

✅ High toughness, good impact resistance

✅ High strength, suitable for high-pressure systems

Processing Complexity

High, requires precise molding

Low, suitable for injection molding

Medium, requires specialized sealing processes

Oil Resistance

Moderate

Moderate, requires additional sealing

✅ Excellent (long-term oil contact)

Cost

Medium

✅ Low, suitable for mass production

❌ High, specialized for hydraulic systems

 

4. Processing Method Comparison


Processing Type

Thermoset Coil

Thermoplastic Coil

Hydraulic Coil

Molding Method

Compression molding, casting

Injection molding, extrusion

Injection molding + sealing treatment

Sealing Method

Epoxy resin potting, fully sealed

Partial sealing with O-rings or gaskets

Typically uses epoxy potting or sealing adhesives

Repairability

Non-repairable after curing

Repairable through welding, cutting, reshaping

Typically does not require repairs

 

5. Application Scenarios


Application Field

Thermoset Coil

Thermoplastic Coil

Hydraulic Coil

Automotive

Engine control systems, brake systems

Dashboard, electric windows

Transmission control valves, power steering systems

Industrial Automation

High-temperature environments, chemical equipment

General solenoid valves, pneumatic equipment

Hydraulic systems, hydraulic solenoid valves

Outdoor Equipment

Power equipment, outdoor control boxes

Photovoltaic systems, outdoor solenoid valves

Hydraulic lifts, oil control valves

Hydraulic Equipment

Rarely used

Rarely used

✅ Widely used in hydraulic systems

 

6. Advantages and Disadvantages Summary


Coil Type

Advantages

Disadvantages

Thermoset Coil

High heat resistance, chemical resistance, excellent dimensional stability

Low toughness, complex processing, non-repairable

Thermoplastic Coil

Low cost, flexible processing, high toughness

Lower heat and chemical resistance compared to thermoset materials

Hydraulic Coil

High pressure resistance, oil resistance, excellent waterproofing

High cost, complex sealing requirements

 

7. How to Choose the Right Coil Type?


Application Requirement

Recommended Coil Type

Reason

High-temperature environments (above 150°C)

Thermoset Coil

Excellent heat resistance, suitable for harsh environments

Mass production and low cost

Thermoplastic Coil

Easy to process, suitable for quick production

Hydraulic systems (high pressure, oil resistance)

Hydraulic Coil

Excellent oil and pressure resistance, designed for hydraulic systems

Outdoor or humid environments

Thermoset Coil / Hydraulic Coil

Both can achieve IP67 waterproof protection

 

8. Conclusion


- Thermoset Coils are suitable for high-temperature and chemical-resistant environments, but their processing is complex and non-repairable.

- Thermoplastic Coils are suitable for mass production and general industrial applications due to their low cost and high toughness.

- Hydraulic Coils are specifically designed for hydraulic systems, with high pressure, oil, and water resistance, making them the preferred choice for hydraulic valves​.

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