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.
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. |
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.
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.
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.
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.
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.
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.
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).
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.
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.
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 |
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.
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.