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At a Glance: Key Applications
Use Megapoxy 34 for: Encapsulating transformers and coils, potting sensitive electronic circuits, casting switchgear components, and sealing underground electrical cable joints.
Megapoxy 34: A Technical Overview
Megapoxy 34 is a high-performance, two-component liquid epoxy resin system, specifically engineered for the critical demands of the electrical and electronics industries. Its formulation as a low-viscosity, 100% solids liquid ensures flawless penetration and encapsulation of intricate components, curing to a solid, void-free mass. This system is designed to provide a dual layer of protection: superior electrical insulation and robust mechanical strength. Conforming to AS3100-1990 for encapsulating and potting electrical components, Megapoxy 34 delivers quantifiable performance for applications where reliability and safety are non-negotiable.
Comparative Performance Overview
| Metric | Megapoxy 34 | Standard Potting Silicone | Advantage |
|---|---|---|---|
| Dielectric Strength | 315 kv/cm | ~200 kv/cm | Offers significantly higher electrical insulation, providing a greater safety margin and reliability in high-voltage applications. |
| Compressive Strength | 90 MPa | <1 MPa (Flexible) | Creates a rock-solid, rigid encapsulation that provides supreme protection against mechanical shock, impact, and vibration. |
| Peak Service Temperature | 150°C | ~120°C | Maintains its structural and insulating properties at higher operating temperatures, crucial for power components and transformers. |
| Viscosity (Mixed) | 905 cps (Low) | Variable (Often higher) | The low viscosity ensures excellent flow and penetration into complex assemblies, eliminating air voids for a perfect, monolithic cast. |
Using Megapoxy 34 in a Complete System
Megapoxy 34 is designed to become an integral structural and insulating part of the final electronic or electrical assembly. Its successful application within a system is contingent on meticulous surface preparation. All surfaces to be encapsulated must be scrupulously cleaned with a non-residual solvent like acetone or isopropyl alcohol to remove any impurities that could inhibit adhesion. Once cured, Megapoxy 34 does not merely coat the components; it fuses with them to create a single, solid component with enhanced mechanical resilience and complete electrical isolation, ready for service in harsh environments.
How Megapoxy 34 Prevents Common Failures
Common failure prevention information
Failure Mode: Dielectric Breakdown & Short-Circuiting
With an exceptional dielectric strength of 315 kv/cm, Megapoxy 34 provides a robust insulating barrier that prevents electrical arcing between components, even in high-voltage circuits. This is a critical safeguard against catastrophic short-circuits caused by moisture or contaminants.
Failure Mode: Component Damage from Vibration & Shock
The cured epoxy forms a rigid, monolithic block with a compressive strength of 90 MPa. This rock-solid encapsulation locks all components in place, protecting delicate solder joints, wires, and sensitive electronics from failure caused by mechanical shock, impact, and sustained vibration.
Failure Mode: Incomplete Potting & Air Voids
Its low mixed viscosity of 905 cps ensures the resin flows freely and deeply into the most intricate parts of an assembly. This eliminates trapped air bubbles, which can attract moisture and create weak points in the insulation, guaranteeing a complete and homogenous encapsulation.
Core Features & Specifications
- High Dielectric Strength (315 kv/cm): Provides an exceptional level of electrical insulation, ensuring component safety and reliability in high-stress electrical environments.
- Excellent Volume Resistivity (10¹³ ohm.cm): Minimises current leakage across the material, preserving the efficiency and integrity of the encapsulated circuit over its service life.
- High Compressive Strength (90 MPa): Cures to a mechanically rigid solid, offering superior protection from physical impact, shock, and vibration.
- Low Viscosity (905 cps Mixed): Ensures easy pouring and complete, void-free penetration into complex electronic assemblies and cable joints.
- High Peak Service Temperature (150°C): Maintains its integrity at elevated temperatures, making it suitable for encapsulating power transformers and other heat-generating components.
- 100% Solids, Nil VOC: A solvent-free formula that cures without shrinkage, ensuring a dimensionally stable cast and a safer working environment.
The Megapoxy 34 Advantage
- Engineer with Verifiable Confidence: Use a product that is certified to AS3100-1990, ensuring your encapsulated components and cable joints meet a recognised Australian standard for performance and safety.
- Deliver Ultimate Reliability: The combination of high dielectric strength and robust mechanical protection ensures components are shielded from both electrical faults and physical damage.
- Achieve Perfect Encapsulation: The low-viscosity formula flows where others can't, guaranteeing a complete, void-free potting that leaves no weak points for moisture or electrical failure.
- Optimise for High-Power Applications: With a peak service temperature of 150°C, Megapoxy 34 is the ideal choice for potting transformers and power supplies where heat dissipation and material stability are critical.
Applications in Practice: Trade Scenarios
For Electrical Engineers: Potting a Custom Power Transformer
The Engineering Challenge: A newly designed transformer requires complete environmental sealing and mechanical support for its windings, along with guaranteed electrical insulation to prevent internal arcing under load.
The System-Based Solution with Megapoxy 34: After preparing the transformer housing and components, pour the mixed, low-viscosity Megapoxy 34 to fully encapsulate the core and windings. The resin flows into every void, curing to a solid 90 MPa block that resists vibration, while its 315 kv/cm dielectric strength provides insulation far exceeding the operational requirements.
Best Practice Note: For best results, consider pulling a light vacuum on the assembly during or after pouring to assist in removing any stubborn air bubbles from the transformer windings.
For Cable Jointers: Sealing a Critical Underground Cable Joint
The Engineering Challenge: Creating a fully waterproof, mechanically robust, and electrically sound seal for a high-voltage underground cable joint that must withstand ground pressure and moisture for decades.
The System-Based Solution with Megapoxy 34: Use Megapoxy 34 to completely fill the jointing shell or mould around the prepared cable connection. It cures to form a 100% solids, impermeable barrier that prevents water ingress and resists chemical attack from the soil. Its dielectric properties ensure the long-term integrity of the electrical connection, in full conformance with AS3100-1990.
Best Practice Note: Ensure the 4 parts A to 3 parts B mix ratio is measured accurately by volume or weight. An incorrect ratio will compromise the cure and all final electrical and mechanical properties.
Certifications & Regulatory Compliance
Megapoxy 34 is specifically engineered and tested to conform to **AS3100-1990**, including amendments 1 and 2, for the encapsulating and potting of electrical components and cable joints. This certification provides third-party validation of its suitability for critical electrical applications in Australia. The product is a Nil V.O.C. (Volatile Organic Compounds) formulation and all its components are listed on the Australian Inventory of Chemical Substances (AICS).
Storage & Shelf Life Considerations
Store Megapoxy 34 kits in a cool, dry, and well-ventilated location, ensuring they are kept out of direct sunlight to maintain product stability. Containers should be kept tightly sealed when not in use. Part B is a toxic and corrosive substance and must be stored locked up in accordance with relevant state regulations. Adhering to these storage conditions is vital for ensuring the product performs to its specified technical characteristics.
Frequently Asked Questions About Megapoxy 34
Q: How does the low viscosity of Megapoxy 34 benefit the potting process?
A: The low mixed viscosity of 905 cps allows the resin to flow like a thin liquid, penetrating into the tightest spaces around complex components. This ensures a complete, void-free fill, which is critical for eliminating air pockets that can trap moisture and create electrical weak points, leading to component failure.
Q: Is this product suitable for high-voltage applications?
A: Yes. Its primary feature is an extremely high dielectric strength of 315 kv/cm. This provides an exceptional degree of electrical insulation, making it an ideal choice for encapsulating high-voltage transformers, power supplies, and other components where preventing electrical arcing is paramount.
Q: What happens if the 4:3 mix ratio is not measured correctly?
A: The 4 parts A to 3 parts B mix ratio is critical and must be precise. An incorrect ratio will lead to an incomplete chemical reaction. This can result in the epoxy failing to cure properly, remaining soft or sticky, and it will not achieve its specified dielectric strength, compressive strength, or thermal resistance.
Q: What is the main difference between Megapoxy 34 and a standard epoxy adhesive?
A: While both are epoxies, Megapoxy 34 is not an adhesive but a casting resin engineered for electrical insulation. Its key properties are its certified dielectric strength, volume resistivity, and low viscosity for potting. Standard epoxy adhesives are formulated for bond strength, not electrical performance.
Applications & Benefits
| Application / Use Case | Key Benefit | Primary Trades |
|---|---|---|
| Underground Cable Jointing | Creates a 100% solid, waterproof, and electrically insulating seal (AS3100-1990). | Cable Jointers, Electrical Contractors |
| Encapsulation of Transformers & Coils | Provides high dielectric strength (315 kv/cm) and heat resistance (150°C). | Electronics Manufacturers, Electrical Engineers |
| Potting of Electronic Circuits | Protects against moisture, shock (90 MPa strength), and vibration. | Electronics Technicians, OEM Manufacturers |
| Casting of Switchgear Components | Cures to a rigid, dimensionally stable component with excellent insulation. | Switchgear Manufacturers, Asset Maintenance |
Applying Megapoxy 34: Protocols & Best Practices
General Application Steps:- Preparation: Ensure all components and housings are clean, dry, and prepared as per the Adhesion & Preparation Guide. Seal any openings in the housing where the liquid resin could leak out.
- Measuring & Mixing: Accurately measure 4 parts of Part A and 3 parts of Part B by volume or weight. Mix thoroughly in a clean container for several minutes, scraping the sides and bottom, until the mixture is uniform and streak-free.
- Pouring: Pour the mixed resin slowly and steadily into the housing or mould from one side. This allows air to escape from the other side, minimising bubbles. Pour until all components are covered to the desired depth.
- Curing: Allow the casting to set for 6 hours at 25°C, during which it should remain undisturbed. A full cure with final properties is achieved after 24 hours at 25°C. Lower temperatures will extend the cure time.
For Electrical Engineers: Potting a Custom Power Transformer
The Engineering Challenge: A newly designed transformer requires complete environmental sealing and mechanical support for its windings, along with guaranteed electrical insulation to prevent internal arcing under load.
The System-Based Solution with Megapoxy 34: After preparing the transformer housing and components, pour the mixed, low-viscosity Megapoxy 34 to fully encapsulate the core and windings. The resin flows into every void, curing to a solid 90 MPa block that resists vibration, while its 315 kv/cm dielectric strength provides insulation far exceeding the operational requirements.
Best Practice Note: For best results, consider pulling a light vacuum on the assembly during or after pouring to assist in removing any stubborn air bubbles from the transformer windings.
For Cable Jointers: Sealing a Critical Underground Cable Joint
The Engineering Challenge: Creating a fully waterproof, mechanically robust, and electrically sound seal for a high-voltage underground cable joint that must withstand ground pressure and moisture for decades.
The System-Based Solution with Megapoxy 34: Use Megapoxy 34 to completely fill the jointing shell or mould around the prepared cable connection. It cures to form a 100% solids, impermeable barrier that prevents water ingress and resists chemical attack from the soil. Its dielectric properties ensure the long-term integrity of the electrical connection, in full conformance with AS3100-1990.
Best Practice Note: Ensure the 4 parts A to 3 parts B mix ratio is measured accurately by volume or weight. An incorrect ratio will compromise the cure and all final electrical and mechanical properties.
Limitations & Safety
Product limitations and safety information
Limitations:
- This is a rigid casting resin, not a flexible coating or adhesive.
- The 30-minute pot life at 25°C is fixed. Do not mix more material than can be poured within this time.
- Properties are specified at 25°C. Higher ambient temperatures will reduce pot life and cure time.
- The mix ratio of 4 parts A to 3 parts B is not optional and must be followed precisely.
Safety & Handling:
- Danger: This product is a Hazardous Chemical and Dangerous Good. Part B is toxic, corrosive, and can be fatal if inhaled. Extreme caution is required.
- PPE: Wear chemical resistant clothing, nitrile gloves, and chemical splash goggles with a face shield. Work must be conducted in a well-ventilated area.
- Ventilation: Use with local exhaust ventilation. Do not enter confined spaces where vapour may have collected.
- Handling: Avoid all contact with skin and eyes. Do not breathe vapours. Do not eat, drink or smoke when using. This product is for professional, industrial use only.
Megapoxy 34 Adhesion & Preparation Guide
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Substrate preparation guidelines
- General Principle: Good adhesion can only be achieved if surfaces to be encapsulated or cast are meticulously clean. Any surface impurities (oils, dust, mould release agents) can reduce bond strength or inhibit the bond entirely.
- Recommended Method: Clean all surfaces thoroughly by wiping with a non-residual solvent such as acetone or isopropyl alcohol. Ensure the solvent has fully evaporated before pouring the epoxy.
- Metals (Housings, Terminals): Degrease with acetone or isopropyl alcohol to remove any machine oils or contaminants. Lightly abrading the surface can improve mechanical keying.
- Plastics & Cable Sheathing: Ensure surfaces are clean and dry. Test adhesion on a small, non-critical area first, as some low-energy plastics may require special primers.
- Prohibited Methods: Wire brushing is not an adequate surface preparation method and will likely result in poor adhesion. Do not use oil-based cleaners.
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