Epoxy Resin Composition for Capacitor Dissimilar Material Sealing
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Solution Overview
Problem
Joining dissimilar materials like metallic and non-metallic components in capacitor tanks is challenging due to resistance to conventional methods, requiring a stronger and more reliable sealing solution that can withstand harsh environmental conditions and prolonged exposure to aromatic dielectric fluids.
Innovation Solution
The use of an epoxy resin composition, specifically comprising phenol novolac or bisphenol A epoxy with a curing agent, is applied to form a cured seal between insulating and metallic components, which is then exposed to aromatic compounds, demonstrating improved joint strength and sealing integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If soldering is used to join capacitor bushings to metallic components, then joint strength is improved, but manufacturing complexity and cost increase significantly
Solution Approach 1:
The patent introduces a specialized adhesive composition as an intermediary substance between the capacitor bushing and metallic terminal cap. This adhesive serves as a mediator that creates a strong bond without requiring the complex soldering process, thereby maintaining joint strength while reducing manufacturing complexity
Solution Approach 2:
The patent replaces the mechanical/thermal soldering system with a chemical bonding system using adhesive composition. This substitution eliminates the need for complex soldering procedures including surface preparation, adhesive application, and curing, while achieving comparable or superior joint strength
2Ease of manufacture
If mechanical fasteners are used to join metallic and non-metallic surfaces, then ease of manufacture is improved, but joint strength and sealing integrity deteriorate
Solution Approach 1:
The patent merges the functions of mechanical fastening and sealing into a single adhesive bonding process. The adhesive composition simultaneously provides structural strength and sealing integrity, eliminating the need for separate mechanical fasteners and gaskets while maintaining ease of manufacture
Solution Approach 2:
The patent employs a composite adhesive system consisting of multiple polymer components (polyester resin, polyacrylate, and carboxymethyl cellulose) that work together to provide both mechanical strength and sealing properties, achieving the combined benefits of structural integrity and environmental protection
3Ease of manufacture
If conventional joining methods are used for dissimilar materials, then ease of manufacture is maintained, but reliability under harsh environmental conditions deteriorates
Solution Approach 1:
The patent modifies the chemical parameters of the adhesive composition by incorporating specific polymers and additives that enhance resistance to thermal cycling, moisture, and aromatic compounds. This parameter optimization ensures reliable performance under harsh environmental conditions while maintaining the simplicity of the manufacturing process
Solution Approach 2:
The patent replaces expensive, complex joining systems with a cost-effective adhesive solution that provides long-term reliability. The adhesive composition is designed to withstand the operational lifespan of the capacitor under various environmental stresses, eliminating the need for expensive mechanical fastening and sealing systems
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The epoxy resin composition provides a strong, reliable seal that withstands harsh environmental conditions and prolonged exposure to aromatic dielectric fluids, maintaining integrity and electrical properties over the capacitor's lifespan.
Implementation Method 1
The epoxy resin composition provides adhesiveness to a metal and having high organic solvent resistance... the resin composition... shows adhesiveness to a terminal or a collector made of a heat resistant metal such as stainless steel and nickel
Implementation Method 2
The epoxy resin composition can comprise a phenol novolac epoxy, a bisphenol A epoxy, or a combination thereof, and a curing agent
Data Source
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AI summary
An epoxy resin composition is disclosed for joining dissimilar materials. The identified epoxy resin compositions can be used to seal metallic and non-metallic components of a capacitor. Specifically the epoxy resin composition can be applied to joints between a non-metallic capacitor bushing and a metallic tank cover and metallic terminal cap. Once the epoxy resin composition is cured, it can provide a seal that can withstand the stresses and environmental conditions to which a capacitor is subjected.