Electrical Resins for today and tomorrow

Switch mode power supply

Mr. Sean McCabe
Altana Electrical Insulation, Zhuhai

Abstract--There is currently a need for magneto-electrical
apparatus such as inductors and transformers that operate
at hundreds of kHz up to several MHz, or even higher
frequency. With this increase in frequency comes the need
for electrical insulating materials with increased
performance and sustainable lifetimes.
The purpose of this paper is to introduce electrical insulation
resins present and future, and assist the electrical engineer in
making a proper selection of impregnating varnish based on
the current and future environmental issues, as well as
maintaining a quality standard of mechanical and electrical
properties in a finished transformer.
are made from "mutually coupled" coils where the
magnetic field established in one coil, ' cuts' through the
other coil and hence induces a voltage in the other coil.
This is called 'mutual inductance'. They are used in
electronics to step-up or step-down voltages. When a
varying voltage (like AC) is applied to one of the coils of
the transformer a voltage is 'induced' in the other coil due
to mutual inductance.

I. Introduction

T ransformers is an important components for power

conversion. The resin requirement is especially
important for fixing, isolation and certification. The
market size of electronic transformer is increasing rapidly.
Altana have estimated that the market growth is 20% from
1999 to 2004 and 10-15% from 2005 onwards. The
explanations for this are as follows:
1. This market is dominated by USA companies who
have OEM in China plus Taiwanese & Japanese bases. Figure 1: Simple transformer function
They continue to move production to China
2. This is the first industry in our field to absorb the II. History and Development of Switched-Mode
foreign investment in China since their end product is Power Supplies
highly labour intensive.
3. The future growth will be the growth of the Chinese
With the introduction of the transistor in the early
domestic market for export.
1950's, and with the development of integrated circuits
4. OEM and / or foreign manufacturers focus on export
but products have to be UL approved. from the early 1960's onwards, designers of electronic
5. Many manufacturers have specified Altana materials equipment and instrumentation have increasingly
demanded smaller, more efficient power to supply their
Electronic transformers are also known as equipment. Therefore, to meet these high demands, the
transformers. Transducers, lightning and surge protection power supply itself has become more and more intricate.
devices, ballast/lighting, capacitors/suppressors and In fact developments in power supply technology can be
switch gear. They are used in telecommunications, office directly linked to the introduction of various power
equipment, automotive, appliances – in fact, the control semiconductor devices, even though the theory, in many
circuit of anything electrical. cases, already well known.
Inductance is the ability of a coil to establish (or induce)
a voltage within itself to oppose changes in current Power supply technology can be divided into two
through its windings. When varying current (AC) flows forms; firstly, the linear regulator and, secondly, the
through a coil, a voltage is induced within the coil in a switched-mode conversion technique.
direction so as to oppose the change of current through it. Historically, linear regulators were very common
Transformers are one of the major applications. These during the late 1950's and early to late 1960's when power
supplies using switching techniques were extremely
Mr. Sean McCabe is head of Technical Department Impregnating uncommon.
Resins and Compounds, Altana Electrical Insulation, Zhuhai The pre-eminence of switched-mode power is directly
.
linked to the development of high voltage switching
transistors circa 1966 and on developments in ceramic
ferrite materials and capacitor knowledge.
III. Future trends
Most commercial switch-mode power supplies in the
market today operate in the frequency scope of 10 kHz to
50 kHz. There is now growing tendency in research work
and new power supply designs of increasing the switching
frequencies to 100 kHz and above.
In addition, developments in new geometries, which
aid the move to higher operating frequencies and
therefore reduce overall size have become prevalent. The
driving force in every manufacturer's design will always
be combined component manufacture and production
costs. Therefore, any new device will have to justify its
existence based on mainly commercial grounds.
IV. Power Transformers - Switch Mode
What differentiates a power transformer and a switch
mode power transformer from other transformers?
Power transformers are essentially A.C. (alternating
current) devices. They cannot uphold transformer
operation from a fixed D.C. (direct current) voltage
source. Switch mode power transformers are used
extensively in electronics, usually within a switch mode
power supply. A switch mode power supply is usually
operated from a D.C. source, such as a battery. The
switching mode power supply converts the input D.C. to
other output D.C. sources.
V. Resin
A. Functions
‹ Transformers are noisy! : Electrical varnishes help
the unit resist vibration.
‹ Transformer consolidation: Electrical varnishes help
the unit resist wire separation, by solidifying the core and
holding the conductors together within the coil.
‹ Environmental: Electrical varnishes insulate the
winding / core from the environment. This insulation
prevents the oxidation of core material and deterioration
of magnet wire insulation.
‹ Insulation of minute "nicks" on the magnet wire,
increased dielectric strength of enameled wire and fibrous
and porous sheet insulation.
‹ Raised operating temperature of low-temperature
sheet insulation.
‹ Fill of internal voids within the component: Playing
a major role in heat transfer from "hot spots" within the
part to the surface.
B. Requirements
‹ Flexible: To aid noise reduction and prevent wire
movement
‹ Low viscosity: To facilities penetration between fine
wires.
‹ Low exotherm /shrinkage: To prevent damage to fine
wires and limit changes in inductance
‹ High chemical and moisture resistance: To repel the
environment
‹ Increased electrical performance: Dielectric strength
for resistance to current.
‹ Increased thermal conductivity: Dissipate heat
quickly and prevent hot spots.
‹ Correct Coefficient of Thermal Expansion: Solids
expand in response to heating and contract on cooling;
this response to temperature change is expressed as its
coefficient of thermal expansion
C. Functions in detail
1. Flexiblility to aid noise reduction and prevent wire
movement: The resin used must be able to “flex”
according to the frequency power of the transformer to
prevent micro-cracking.
Flexibility is measured using:
‹ Hardness Measurements DIN 53505
‹ Tensile strength ISO527
‹ Glass transition temperature IEC1006
Fig. 2 shows micro-cracking from the wrong choice of
resin.
Fig 2: Enlarge picture of Resin
2. Viscosity: Viscosity is the measure of a material's
resistance to flow. It is a result of the internal friction of
the material's molecules. Materials with a high viscosity
do not flow readily; materials with a low viscosity are
more fluid.
3. Low exotherm / shrinkage: To prevent damage to
fine wires and limit changes in inductance when certain
polymers cure they give out heat as an exotherm - the
energy dissipated in a chemical reaction. This heat is
sufficient to break wires and therefore change the overall
inductance
4. Increased thermal conductivity: Dissipate heat
quickly and prevent hot spots. Thermal conductivity is a
measure of the heat transfer capability of the resin to
prevent over-heating of the core. It is measured according
to ISO 8894-1. Inorganic fillers are used to increase this
property but this can also increase viscosity.

5. Correct Coefficient of Thermal Expansion:

Materials expand / contract due to changes in temperature
which leads to changes in thermal vibration of the atoms
in a material, and hence to an increase in the average
separation distance of adjacent atoms. The linear
coefficient of thermal expansion describes by how much a
material will expand for each degree of temperature
increase.

Table 1 shows the current resin profiles.

Fig 3 shows the examples of resins and compounds for

the electronic transformer industry.

Fig 3 Example of resins and compounds for electronic

transformer industry/

Table 1: Resin profiles

 VI. Application of different chemical types

A. Resilient epoxy resin

It is used for impregnation of electronic components. Its
advantages are: outstanding noise reduction, outstanding
thermal dissipation, high dielectric strength, excellent
chemical and moisture resistance, excellent tank stability
and long product history.
The application method is using dip/vacuum process.
Its single component cure time is 3-5 hours in 135°C and
UL recognized up to Class 200C.
It is known as Altana 468 range.

B. Modified saturated polyesters

It is used for impregnation of motors and transformers. Its
advantages are fast air dry, good penetration and good
moisture resistance. The application method is dip, and
spray. The single component cure time is 20-30 minutes
at 25°C. UL recognized up to Class 180C.
It is known as Altana V1630/V1380/009-0008.
C. Solvented saturated polyester
It is also used in impregnation of motors and
transformers. It advantages are high flexibility, high bond
strength and good moisture resistance. The application is
dip and VI. Single component cure time is 2-3 hours at
130-160°C. UL recognized up to Class 200C.
It is known as Altana 003-1010.
Fig 4: Example of potting application in PED300.
F. Highly filled epoxy resin
This type is also used in impregnation and potting of
transformers. It advantages are minimal exotherm and
shrinkage, excellent for noise dampening, highly filled
giving excellent heat transfer, long pot life and low
viscosity making this compound ideal for fine wire
applications. The application is potting. Dual
component (100:15) cure time is 24 hours at 25°C. It is
recognized by UL up to UL94 V-0.
It is known as Altana E471-5LL.
Fig 5 shows some example of potting with E471-5LL.

D. Flexible polybutadiene

It is also used in potting of electronic components. It

advantages are very flexible, good adhesion to various
substrates, excellent thermal shock characteristics and
room temperature cure. The application is potting. Dual
component (100:24pbw) cure time is 72-168 hours at
25°C. It is not UL recognized.
It is known as Altana U510S.

E. Unsaturated polyester –in styrene.

It is also used in impregnation and potting of

transformers. It advantages are very flexible, excellent
for noise dampening, can be highly filled, excellent field
history and cost effective. The application is potting.
Dual component (100:1) cure time is 248 hours at 25°C.
It is recognized by UL up to class 180C.
It is known as Altana PED300.
Fig 4 shows a typical potting application in PED300
Fig 5: Example of transformer potting in E471-5LL
G. Filled polyurethane resin
It is also used in impregnation and potting of high voltage
electric and electronic transformers. It advantages are
good electrical properties ate elevated temperatures,
excellent mechanical resiliency, excellent heat shock and
low temperature cure. The application is potting. Dual
component (100:16.7) cure time is 1-2 hours at 107-
121°C. It is not recognized by UL.
It is known as Altana 200 Polyurethane.
 VII. Application Techniques
There are several application techniques available to the
engineer depending on the type of transformer to be
processed (some mentioned in section VI).
1. Dip and Bake
This is simply what it says – the component is
immersed into the varnish for a quoted period of time (dip)
depending on construction (wire size etc). The wet
transformer is withdrawn and placed into a pre-heated
oven for a designated time period. Some applications can
be conveyorised.
Figure 6: Conveyorised dip and bake cycle
2. Vacuum Impregnation
This process is used when very fine wires are present. The
vacuum draws the resin into the windings so that
complete impregnation is achieved. The wet transformer
is withdrawn and placed into a pre-heated oven for a
designated time period; refer figure 7
Figure 7: Simple VPI pictogram
2. POtting Application
This application features heavily in the electronics
industry where a pre-determined mass of resin is weighed
manually, or dispensed via a mixer/metering machine into
a moulded vessel.
The subsequent mass is either cured at room temperature
or heated in a pre-heated oven.
VIII. Future development
A. Environmental driven
Future resin development is essentially environmentally
driven. Water based resins, low emission resins and low
viscosity, solventless epoxy systems are advantageous.
EPA programs have been set up to improve air quality.
The clean air act has added an extra dimension in making
a decision as to the type of varnish to use in the
manufacturing of transformers and other electrical devices.
Fig 8 shows the typical % of VOC (Volatile Organic
Compound) for each type of varnish.
Fig.8. Typical % of VOC (Volatile Organic Compound) for
each type of varnish.
Fig 9 below shows the % volatiles stripped off under
vacuum levels of 10 and 20mmHg. The solvent based and
water based systems were not tested as a result of the
vapour pressure of these solvents. The solventless epoxy
and DAP systems exhibited good results
Fig 9: Chemical loss under vacuum
B. Temperature rating driven
Filled resins to improve thermal conductivity are
required. High Temperature co-polymer systems and High
Temperature Epoxy Resins are also important.
Fig 10 shows the temperature rise comparison of different
resins. Note that the acceptable upper limit for heat rise in this
case was 150C.
Figure 10: Temperature rise comparison
The transformer processed in the solvent-less epoxy
exhibited heat rise of 20C less than the other systems.
The reason for this is that the solvented polyester and the
water based varnishes didn’t meet the temperature
requirement of 150C for the transformer is that when
these are cure they also out-gas. These emissions cause a
honeycomb effect, trapping air which is a poor thermal
conductor and traps heat.
Fig 11 shows how the correct choice of impregnant
even amongst different 100% solids varnishes of like and
dissimilar chemistries, can have varied results pertaining
to heat rise.
Fig 11: Heat reduction comparison
The correct choice of resin has a direct effect on the
heat rise of the transformer. Whilst this is a physical
function of the varnish, the results directly impact the
decision of the varnish choice by reflecting into the final
cost of the transformer.
How does heat rise and heat reduction calculate into the
costing factor of the varnish? Providing that the heat rise
is within specified limits, the engineer will be able to
achieve a significant cost reduction of the transformer by
eliminating some of the core steel and magnetic wire. The
major cost of the transformer is in the insulation, steel and
copper. If you can eliminate even a small percentage the
cost savings are real.
C. Actual costs of Typical Varnishes
The actual cost of a varnish does not stop at the retail
value. Questions need to be asked such as; what is the
actual useable non-volatile content? What is the cost of
maintaining the varnish? What is the actual cost of the
varnish?
The retail value does not actually reflect the ACTUAL
cost of the varnish. In fact a more expensive varnish can
actually cost the same as, or in some cases less than a
low-priced varnish.
The most accurate way to evaluate this cost is by volume.
Whilst there are different sizes of transformers, they
should all have the same relative volume capacity i.e. they
will accept the same amount of varnish by volume.
Whilst the typical price of the solvented varnish (below)
is $10.75 per gallon the following will show that this is
not the actual cost:
1 gallon of varnish (50% NVM) = 231in3
Evaporation of solvent during cure = 115 in3
Loss of varnish (drain and cure) = 15 in3
Total losses = 130 in3
This means that from 1 gallon of varnish purchased the
amount recovered (useable) = 101 in3 (44%)
ACTUAL COST = 0.11CENTS PER in3
In comparison a relatively expensive, solventless
vacuum impregnation epoxy $22.76 per gallon was
studied:
1 gallon of varnish (100% NVM) = 231in3
Loss of resin under vacuum = 0 in3
Evaporation during cure = 2 in3
Loss of varnish (drain and cure) = 60 in3
Total losses = 62 in3
This means that from 1 gallon of varnish purchased the
amount recovered (useable) = 169 in3 (73%)
ACTUAL COST = 0.14CENTS PER in3
Others

It is clear that different applications require different

properties from the resin system used. It is beneficial to
investigate what exact properties are important and define
in order of importance. Also, the resin will be used in
conjunction with other insulation materials; therefore
good compatibility between these is essential.
Compatibility checks include the wet state and by-
products after cure due to thermal degradation

Primary considerations are:

‹ Mechanical and Electrical Properties
‹ Endurance Properties

Others include:

‹ COSHH – Control of Substances Hazardous to Health.

These place obligations on employers to use more safe
chemicals

‹ EPA – Environmental Protection Act. Limits to the

release of hazardous substances into the environment

‹ COST - This covers the cost of the resin and also the
cost of the equipment

The above constraints forms a pentagon needs as shown

in Fig 12:

Fig 12: Constraints on a system

IX. CONCLUSION

The challenges of performance criteria, cost, and

environmental issues influence the engineer’s decision.

To summarize, the main decisions are the

performance characteristics of the resin, varnish cost,
the cost with disposal of vanish and impact to the
environment such as air quality.
Further possible changes in environmental
legislation also needed to considered for decision
making in the future.