Transformer coils and inductors generate heat during operation, are subject to vibration, and are exposed to moisture and mechanical stress. Potting these components is critical for insulation, thermal management, vibration damping, and long service life.
Why Do Transformers and Inductors Require Potting?
- Moisture accumulation and corrosion between winding conductors
- Winding insulation degradation from vibration fatigue
- Inadequate heat dissipation — hot spot formation
- Mechanical impact damage to conductors
5 Key Criteria for Transformer Potting
| Criterion | Description |
|---|
| Low viscosity | Must penetrate narrow gaps between winding conductors |
| Temperature stability | Formulation must withstand operating temperature |
| Thermal conductivity | High-power transformers may need thermally conductive system |
| CTE compatibility | No stress on winding conductors during thermal cycling |
| Electrical insulation | Dielectric strength appropriate for application voltage |
System Recommendations by Application
| Application | Recommended System |
|---|
| Low-power transformer, ≤80°C | Low-viscosity rigid PU |
| Medium-power transformer, 80–120°C | Epoxy or high-Tg PU |
| High-power transformer | Thermally conductive epoxy or PU |
| Vibrating environment inductor | Elastic PU or NCflex |
| Outdoor transformer | Rigid PU — IP67 target |
Key Application Considerations
- Pre-warming: Warming component and resin to 40–50°C reduces viscosity and improves penetration
- Slow pouring: Pour slowly to prevent air entrapment between windings
- Vacuum degassing: Where possible, degas resin before pouring
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