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Megapoxy 34 is a low-viscosity 100% solids epoxy resin system within the solvents and cleaners category specifically engineered for potting and encapsulation in the electrical infrastructure industry. This formulation provides industrial-grade insulation with a dielectric strength of 315 kv/cm and a 90 MPa compressive strength to prevent catastrophic arcing and mechanical failure in high-voltage environments.
It conforms to AS3100-1990 standards, ensuring certified protection for subterranean utility joints and high-temperature transformers where moisture ingress or insulation breakdown would result in structural failure. The low 905 cps mixed viscosity helps deep penetration into complex windings and intricate cable bundles to eliminate air voids and maintain integrity up to 150ºC.
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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