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A Quick Check List to Determine the Cause of Cracking in an Epoxy or Urethane Cast Component:

If the problem is recent, the Number 1 step is to check if anything has changed in your process. Do not assume! Check! - Take the show me how you do it approach!

 

Basic Considerations for Encapsulating Magnetic Components using Epoxy or Polyurethane Systems

 

Things to keep in mind:

  • Polyurethanes tend to have shorter pot life and, as a rule, exhibit more shrinkage during cure
  • Unfilled product tend to have higher CTE’s which may result in broken wires, cracked cores and / or a change in filled products exhibit less shrinkage, lower CTE and better thermal conductivity.
  • In most cases, the pot life (working time) can be adjusted by a slight alteration in the chemistry, with Epoxy systems having a wider range in this regard.

 

What are Castable Urethane Elastomers?
Castable Urethane ELASTOMERS are materials which can be stretched and will recover instantaneously on release. They are thermosetting, as are natural and synthetic rubbers. In simple terms, an Elastomer is a material which can be stretched at room temperature to twice its own length, held for five minutes, and upon release, will return to within 10% of its original length over a period of time.

Why is the Glass Transition Temperature and CTE important?

 

In Electronic and Electrical assemblies, why is the Glass Transition Temperature and CTE important when selecting a Polyurethane or Epoxy System?

 

In demanding electrical/electronic applications, thermosetting epoxies and polyurethanes may be used to bond components or hermetically seal the assemblies through a potting or casting process. In operation, these assemblies will experience some form of thermal cycling, whether it be through heat generation, or through an environmental temperature change. Due to these thermal changes, a polymers T(g) (glass transition temperature) and CTE (co-efficient of thermal expansion) should be factored into the decision tree when selecting an appropriate polymer system.

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