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DAMPNG VS TEMPERATURE
O.3 OL - MODIFIED GILSONTE
2OOO HE PLATE
O. 2
O.
2O 4.O 6O 8O OO
TEMPERATURE, c
O.3 E 3
DAMPING VS TEMPERATURE
BLOWN ASPHALT
2OOO Hz PLATE
2O 4O 6O 8O OO
TEMPERATURE, C
1
4,022,635 2
8. Energy consideration - Blown asphalts are de
MODIFIED ASPHALTTE POTTING rived from petroleum oils by methods well known in
COMPOSITION the art; in light of rapid world consumption pf petro
BACKGROUND OF THE INVENTION
leum and the dwindling supplies thereof and ecological
concern, it is desirable that the potting compound be
1. Field of the Invention wholly comprised of, or at least based upon, a material
The present invention relates to an encapsulating which is not a petroleum derivative.
system useful in inductive electrical devices, and more A coil impregnant, in addition to embodying the
particularly, to a potting compound and a coil impreg properties set forth in paragraphs 1, 2, 3, 4, 5, 6 and 8
nant useful in a ballast for at least one gaseous dis O above, should confrom desirably to the following:
charge lamp. 1. Should be able to wet the coils and flow between
2. Description of the Prior Art the laminations and coil turns so as not to leave any air
Asphaltic materials, usually in the form of blown bubbles;
asphalts, have been accepted as potting compounds 2. Should be solderable with resin flux; ie, without
and coil impregnants and are presently in general use. 15 having to strip, mechanically or chemically, the im
While satisfactory in many applications, asphaltic ma pregnant material from terminals and wires to be
terials have many limitations and are definitely defi soldered; and
cient for many other applications. 3. Should, during manufacture of the device, not
A potting compound is often used in conjunction produce vapors which are photochemically active or
with a metal receptacle for encapsulating transformers, 20 otherwise deleterious to the environment. . .
inductors and the like which generally are characteris Upon consideration of these requirements, it be
tically small size components. The physical property comes apparent why the art only rarely yields an im
requirements of and considerations for such a potting proved encapsulating system and why the asphaltic
compound are diverse; while some essential properties materials have enjoyed such a high degree of accept
25 ability for such a long time. The problem of how to
can be compromised, a successful compound must obtain an improved encapsulating system, ie, potting
embody at least minimal and preferably the highest compound and coil impregnant having improved sound
standard, in each of the following areas: suppression capabilities has persisted and is an indica
1. Sound suppression - Highly important is the tion of the unobvious nature of the present invention.
sound suppression characteristic. The material should 30 It is desirable therefore to provide an encapsulating
have a high degree of sound suppression of the sound system including a potting compound and a coil im
level which might accompany normal operation of the pregnant wherein the above properties are maximized.
electrical device. The purpose is to convert the sound Accordingly, it is an object of the present invention
of operation of the device into heat which in turn is to provide a new and improved potting compound
dissipated by the potting compound, an important 35 which will supply certain of the deficiences of the as
property when applied, for instance, to a ballast for phaltic compounds and in particular, a higher level of
fluorescent lighting; sound suppression.
2. Thermal conductivity - The potting compound Another object of the present invention is to provide
should have a high rate of heat transferability since it an encapsulating system including a potting compound
must convey heat as rapidly and efficiently as possible 40 and a coil impregnant which will be sufficiently eco
away from the working components of the electrical nomical, both as a starting material and in method of
device which has been encapsulated; application: ie, basically not a petroleum derived prod
3. Water imperviousnes - The potting compound uct.
should be relatively unaffected by water and should
protect the components from the adverse effects of 45
water;
SUMMARY OF THE INVENTION
4. Rheological properties - The potting compound provided In accordance with the present invention, there is
a potting compound including a modified
should initially possess a low viscosity and should be asphaltite composition. The modified asphaltite has the
pourable so as to completely fill the receptacle and following properties: a ring and ball softening point of
totally encapsulate the electrical component. Almost 50 from 90° to 125 C, a penetration at 25°C with a 100
immediately, upon contact with the cooler surface of gram mass after 5 seconds of from 0 - 5 mm and a
the compound and receptacle, the viscosity should rheological value as measured at 200° C on a Stormer
increase so that the potting compound will not "run Viscosimeter using a 400 gram mass of from 10 - 100
out' of openings and, during normal operation, should seconds for 100 revolutions. Also included is inert filler
not exude from the receptacle; 55 material having a size of from 20 - 325 mesh to the
5. Dielectric stability - Once formed as a potting extent of from about 45 - 80% by weight of the mix
compound, the material which protects the compo ture.
nents should exhibit a high degree of inertness to the In another aspect of the invention, there is provided,
atmosphere, humidity and termperature changes so in combination, an inductive electrical device having a
that the encapsulated electrical components are ade 60 plurality of electrical components mounted within a
quately protected. Though dielectric properties need container member and a potting compound for potting
not be high, they should be comparable to those of the components in the container member. The potting
blown asphalts. compound includes a modified asphaltite composition
6. Cost - The potting compound must be reasonably having a softening point of from 90 - 125 C, a pene
priced both as a raw material and in its finished form; 65 tration at 25 C with a 100 gram mass after 5 seconds
7. Ease of repair - The potting compound should be of from 0 to 5mm, and a rheological value as measured
capable of being removed by scraping and digging if at 200°C in a Stormer Viscosimeter using a 400 gram
repairs to the electrical components are required; mass of from 10 - 100 seconds for 100 revolutions.
3
4,022,635 4
Also included in the potting compound is silica filler Table I-continued
sized from 20 - 325 mesh to the extent of from about
45 - 80% by weight of the mixture. Physical Properties of Unmodified Gilsonite and Blown Asphalt
Gilsonite
In yet another aspect of the invention, there is pro Selects Blown Asphalt
vided an impregnating compound for electrical coils. Penetration, (mm) per 0-3 24 - 32
Included is about 75 - 85% by weight of a modified ASTM-D5-52, 2.5 C, 100 gm.,
asphaltite composition having a softening point of from 5 sec, 0.0 mm
Viscosity, 200 C,
90- 105 C and about 15-25% by weight of a wax or 100 Revolutions, Stormer (Sec)
like material which will produce a resultant mixture Stormer (Sec)
having the following properties: a softening point of 10 200 gm.
400 gm.
(a)
(a)
26 - 55
3 - 27
from 125-135°C; a penetration at 25°C with a 100 700 gm. . (a) 7- 5
gram mass after 5 seconds of from 5 - 20 mm; and a
viscosity of 170° C of from 70 - 125 centipoise. (a) Too viscous to measure
BRIEF DESCRIPTION OF THE DRAWINGS 15 The blown asphalt has, in addition, the following prop
In the accompanying drawings: erties:
FIG. 1 is a cross-sectional view of a ballast for a Flash Point, F min. - 525
gaseous discharge lamp, the ballast containing a potting Firepoint, F min. - 560
compound and coil impregnant in accordance with the This table shows that unmodified gilsonite is too
present invention; viscous and has too high a softening point for formula
FIG. 2 is a graph showing vibration damping in which tion into satisfactory potting compound. By the present
Critical Damping, % is plotted versus Temperature for invention, gilsonite is modified in the preferred em
oil-modified gilsonite; and bodiments by one of two processes to give the composi
FIG. 3 is a graph showing vibration damping in which tion the following physical properties: a softening point
Critical Damping, 96 is plotted versus Temperature for 25 of from 90 - 125 C as measured with a shouldered
a blown asphalt potting compound. ring in accordance with ASTM-E28-58T, a penetration
DESCRIPTION OF THE PREFERRED at 25 C with a 100 gram mass and a 0.10 mm needle,
EMBODIMENT after 5 seconds, of from 0 - 5 mm, in accordance with
ASTM-D5-52; and a rheological value as measured at
Referring to FIG. 1, there is shown an inductive elec 30 200 C on a Stormer Viscosimeter usng a 400 gram
trical device such as ballast 10 suitable for use with mass of from 10 to 100 seconds for 100 revolutions.
electrical and electronic equipment, and in particular, One form of the preferred embodiment involves the
for ballasting at least one gaseous discharge lamp. Bal addition of a suitable oil such as a process oil. To be
last 10 includes transformer 13 comprising a core 15 satisfactory for this purpose, the oil must have low
and a coil 17. Core 15 and the coil 17 are disposed 35 volatility and be fully compatible with the gilsonite.
within an outer ballast case 19 made of a suitable mate That is, the oil should not vaporize during impregnation
rial such as metal, the components being spaced there or potting and in use, after potting or the like, should
from by means of the potting compound 18 of the not volatilize to condense out on surrounding materials
present invention. The ballast case 19, a container and apparatus. Furthermore, there should be no exuda
member, is in the shape of a retaining box of magnetic 40 tion with aging. An oil found to be adequate for this
sheet metal. The box is usually provided with a cover purpose is an aromatic process oil made by Shell Oil
member 20 which may be removed to gain access to Company and sold under the trade name Dutrex 357.
the components therein. The addition of such oil to constitute about 15 - 30%
In accordance with one aspect of the present inven by weight of the oil-gilsonite mixture is believed suffi
tion, there is provided a potting compound useful in 45
cient to provide a product approximating the proper
such inductive electrical devices, the basic ingredient ties of a suitable blown asphalt.
of which is a modified asphaltite composition, such as, Following is a listing of some typical properties of
for example, gilsonite, to which is added inert filler Shell Dutrex 357:
material. Asphaltites are natural asphalt-like sub
stances characterized by their high fusing point: ie, 50 Viscosity, SSU/100° F - 459
over 100° C. They are grouped into three classes, Viscosity, SSU/210° F - 48.4
namely: gilsonite, glance pitch, and grahamite. All are Specific Gravity/60° F - 0.9972
presumably derived from the metamorphosis of petro Flash Point, c.o.c., F - 395
leum. Gilsonite, or uintaite under which name it is also Pour Point F - 35
known, is found in but one region, the Uinta Basin 55 Volatility, 22 Hrs/225° F % W - 0.4
extending five miles east of the Colorado boundary to Viscosity - Gravity Constant - 0.970
60 miles westward into Utah. Refractive Index/20 C - 1.5720
Unfortunately, gilsonite as mined does not have the It is believed that any process or similar oil having a
proper physical properties for the potting application. viscosity gravity constant greater than 0.90 and a vis
This is illustrated in Table I in which the Selects grade 60 cosity in SSU at 100° C of from 40 to 55 and which is
of gilsonite is compared with a blown asphalt of a type added to the extent of from about 15 to 30% by weight
commonly used to formulate potting compounds. of the oil-gilsonite mixture is satisfactory to produce,
Table I when added to the gilsonite, a composition having suit
able physical qualities for use as a potting compound.
Physical Properties of Unmodified Gilsonite and Blown Asphalt
Gilsonite 65 Another form of the preferred embodiment for modi
Selects Blown Asphalt fication of the gilsonite is thermal depolymerization or
Softening Pt. - Ring and Ball 52 07 - 14 cracking. It is believed that when the gilsonite is heated
(° C) per ASTM-E28-58T at from 350 to 400 C for 80 to 120 minutes in a
S
4,022,635 6
nitrogen atmosphere, a product approximating a suit Table III
able blown asphalt is produced.
Sound Tests of 1022 Balasts Potted in Modified Gilsonites
Those skilled in the art may recognize other methods 02 C
of changing the viscosity of the gilsonite and such are 5 Oil Modified Gilsonite, (db) Depolymerized Gilsonite, (db)
intended to come within the coverage of the appended 12 1.5
claims. 13 6.5
Samples of gilsonite were modified by the addition of 17
6
7.5
4.0
Shell Dutrex 357 oil to the extent of about 21% by O 2.0
weight of the oil-gilsonite mixture as well as by depo O
lymerization by heating the gilsonite at about 360° to 3.6 av. 14.3 av.
380°C for 90 to 100 minutes in a nitrogen atmosphere;
the physical properties of both modified gilsonites are Statistical tests failed to show a significant difference in
compared with those of a suitable blown asphalt in 15 these averages indicating that the oil-modified and the
Table below. depolymerized gilsonites are equally satisfactory in
Table II their sound supressing properties. Accordingly, the
Physical Properties of Modified Gilsonites and Blown Asphalt averages can be pooled to give a value of about 13.95
Depoly
merized O Blown
db for all ten samples and this value can be compared
20 with the approximately 19.5 db monthly average of
Gilsonite Modified Asphalt
Softening Pt. (C) 1 10 O3
quality control audit tests on General Electric Model
O7 - 14
Ring and Ball per ASTM-E28 No. 1022 ballasts potted and impregnated with blown
Penetration (mm) per O- () - 24 - 32 asphalt compositions. The sound improvement of 5.55
ASTM-D5, 25 C, 100 gm., 25 db corresponds to almost a fourfold decrease in sound
5 sec. (). 10 mm needle
Viscosity, 200°C, power. Statistical analysis of the data shown that a 3 db
00 revolutions, Stormer, (Sec) ,
200 grams S) 84 26 - SS
difference in these averages could be expected at about
400 grams 23 4. 3 - 27 95% confidence level which corresponds to a twofold
700 grams 2 2 7- 5 decrease in sound power.
30 In accordance with another aspect of the present
To achieve a lower cost and to improve the thermal pound invention, there is provided an impregnating com
conductivity, the modified gilsonite to be used as a and in for electrical coils based also upon an asphaltite,
particular, gilsonite.
potting compound, for example, for gaseous discharge
35 In one form of the preferred embodiment, the gilson
lamps, is mixed with an inert filler material, preferably ite is modified by depolymerization,
finely divided silica having a size from 20 - 325 mesh plished by heating the material at 350 this being accom
and to the extent of from about 45 - 80% by weight of about 4 - 5 hours in a nitrogen atmosphere - 380 C for
the modified gilsonite-silica filler mixture. Any filler modified gilsonite having a softening point ofto97yield C,
a
as
material which is substantially inert to the asphaltite 40
measured per ASTM-E28-58T. Then, about 15-25%
and oil may be used provided it is an electrical insulator weight of a wax such as ACRAWAXCT (a trade name
and a thermal conductor. Certainly materials such as for ethylenediamine
Fuller's earth, diatomaceous earth, alumina and like bisstearamide - produced by Glyco
materials may be used. Chemical Co.), or like material which will produce the
Samples were made wherein the depolymerized gil 45 results outlined above, is added to 75- 85% by weight
sonite and the oil-modified gilsonite were mixed with of the depolymerized gilsonite. In a sample run, a for
mulation comprising about 80% by weight of gilsonite
about 54% by weight of the 325 mesh silica. The ring
and ball softening point of the depolymerized mixture modified by heating at about 360°C for 4.5 hours in a
was then measured as 117 C and that of the oil-modi 50 nitrogen atmosphere to which was added to about 20%
fied mixture was 120 C. These values are at the lower by weight of ACRAWAX CT, yielded an impregnant
end of the range of 117 to 135° C typical for suitable having a viscosity of 83 centipoise at 170° C as mea
blown asphalts when mixed with this quantity of silica. sured per ASTM-E28, and a dielectric strength of 1150
Five each of General Electric model 1022 ballast volts/mil (short time) as measured per ASTM-D176
transformers (for use with F40T12 fluorescent lamps) 55 56T.
were potted as seen in FIG. 1 in the oil-modified gilson In another form of the preferred embodiment, the
ite formulation and five each were potted in the depo gilsonite is modified by the addition of a suitable oil. It
lymerized formulation using the standard metal case is believed that any oil having a viscosity gravity con
for such ballasts. The core?coils were impregnated with 60 stant greater than 0.90 and a viscosity in SSU at 100°C
an asphalt-wax impregnant based on a blown asphalt, of from 40 to 55 when added to the extent of from
the impregnant having the following properties: about 29 - 36% by weight of the oil-gilsonite mixture
Softening Point, Ring and Ball - 127 - 135°C will produce an impregnant having the desired proper
Penetration, 100gm., 5 sec, 25 C - 30 - 40 mm ties as set forth in the preceding paragraph to which is
viscosity 170°C, - max 70 centipoise The ballasts 65 added a suitable wax as outlined above. Shell Oil Co.
were then sound tested at 102° C in a standard Dutrex 357 was also used for this application. Table IV
fluorescent lamp fixture. The results are shown in shows several formulations resulting from a sample run
Table II. and the properties obtained.
4,022,635
Table IV
Oil-Modified Impregnant Formulations
Oil Wax Viscosity Penetration Softening
Gilsonite % (by wt.) % (by wt.) 170° C, cps t Point, C
Formulation 7% (by wt.) (a) (b) (c) (d) (e)
No. 1 56 24 20 18 9 28
2 54 23 23 10 9 29
3 52 23 25 105 7 130
4. 51 24 25 93 O 28
5 50 25 25 88 2 129
6 49 26 25 83 15 129
7 48 27 25 78 6 29
(a) Dutrex 357
(b) ACRAWAX CT (Ethylcnediaminc bisstcaramide-Glyco Chemicals Co.)
(c) Brookficid Modcl HBT (No. 1 spindlc)
(d) ASTM-D5-52
(e) ASTM-E28-58T
35
40
45
50
55
60
65