Expandable Graphite Sealing Resin for Low-Moisture Film Capacitors
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Solution Overview
Problem
Existing resin compositions for sealing electronic components, such as film capacitors, face challenges in achieving low water absorption rates while maintaining excellent flame retardancy and heat resistance, which are crucial for preventing moisture-induced deterioration.
Innovation Solution
A resin composition for casting that incorporates expandable graphite and a curable component, preferably an epoxy resin, to produce a cured product with low water absorption, excellent flame retardancy, and heat resistance, while maintaining low viscosity for improved workability without the use of solvents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a curable resin composition is used as a sealing portion, then flame retardancy and heat resistance are achieved, but water absorption rate increases causing element deterioration
Solution Approach 1:
The patent uses a composite resin system combining epoxy resin with polyamide resin or polyester resin, creating a multi-phase material structure where each component contributes different properties. The epoxy provides low water absorption and excellent adhesion, while the polyamide or polyester component enhances flame retardancy and heat resistance, achieving a balance between conflicting requirements through material composition rather than single-material optimization
Solution Approach 2:
The patent systematically varies the compositional ratios of curable resin to hardening resin (specifically polyamide or polyester resin) to optimize performance. By adjusting these parameter ranges, the invention achieves the dual goal of maintaining low water absorption rate while attaining sufficient flame retardancy and heat resistance, demonstrating parameter optimization as a key strategy for resolving the technical contradiction
2Ease of manufacture
If solvent-free resin composition is used, then environmental friendliness and handling safety are improved, but viscosity increases reducing filling workability
Solution Approach 1:
The patent controls the viscosity of the solvent-free resin composition by optimizing the molecular weight and structural parameters of the resin components. By selecting specific epoxy resins with appropriate viscosity characteristics and matching them with suitable hardening agents, the invention achieves a balanced viscosity range that ensures good filling workability while maintaining the environmental and safety advantages of a solvent-free formulation
Solution Approach 2:
The patent introduces a catalyst or accelerator as an intermediary substance that enables the curing reaction to proceed efficiently at lower viscosities. This intermediary component facilitates the chemical reaction between epoxy and hardening resin, allowing the composition to maintain fluidity during filling operations while still achieving complete curing and the desired performance characteristics in the final sealed product
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 resin composition effectively suppresses moisture infiltration, ensuring the longevity of sealed elements by achieving a low water absorption rate, excellent flame retardancy, and heat resistance, along with excellent filling workability and handling properties.
Implementation Method 1
containing a curable component and expandable graphite
Implementation Method 2
a cured product of a curable resin composition containing a resin material
Data Source
AI summary
A resin composition for casting, containing a curable component and expandable graphite. A molded body including an element and a sealing portion that seals the element, in which the sealing portion contains the resin composition or a cured product thereof.