Condenser Seal

Our ingenious sealing system for the installation in the inverter

Challenge

Sophisticated condenser seal for all climatic conditions

Easy installation of 18 capacitors required at the same time

Material must meet fire protection guidelines

Lösung

Correct choice of materials and joint testing

Adding a clamping ring to the seal

Creation of an injection mold

Ergebnis

Reliable seal suitable for electronics production

Simple installation of capacitors in the inverter

Seal with a service life of at least 20 years

Easily mountable seal for inverters wanted

A producer in the solar industry, is turning to Jäger Gummi und Kunststoff with a power inverter project. The assembly of capacitors using a self-developed seal with a molded part made of silicone has proven to be too complex, too expensive and with risks for the required tightness. Therefore, the customer is looking for a solution for a simple installation of 18 capacitors simultaneously.

Jäger Gummi und Kunststoff is the right address for this. The engineers and designers prepare FEM calculations to calculate the deformations and required pre-stressing of the seal and then manufacture a steel test mold to provide the customer with test seals made of original material for trials.

In doing so, the customer‘s developers, together with Jäger‘s experts, record exactly where problems still occur in the endurance test. How does the designed gasket behave under different assembly processes and sealing requirements (stresses, temperature differences, expansion behavior, etc.)? The advantages and disadvantages are discussed together and a seal geometry is decided upon.

The developers test the newly created sample gaskets: To do this, they subject the test part to a tightness test (immersion test) overnight and then analyze the exact location and extent of the leakage. Throughout the entire process, all those involved come together again and again. All steps are checked, recorded and new proposals are developed.

Solution

Multi-Part capacitor set for smooth installation

The right choice of material and design is decisive for both the seal and the clamping ring. In addition to the matched silicone compound, POM with glass fibre content is used for the clamping ring. Initial clamping ring prototypes can be produced by a mechanical production process and must be designed for a later planned injection molding and assembly process.

It is a particular challenge to design the clamping ring in such a way that the required elasticity for the assembly process is given. The clamping rings must sit firmly in the sheet metal and press the seals against the sheet metal so that sufficient tightness is ensured. However, the clamping ring must not burst in the process. In order to test the function of the original material and the design envisaged so far, an injection mold of one caliber must be made. To determine the final design of the clamping ring, tool change loops are necessary, all of which can be implemented with the existing tool.

Both products – the seal and the clamping ring – must ultimately allow the entire 18-piece capacitor set to be inserted smoothly in one step. Subsequent adjustment both vertically and horizontally should also be possible at the customer‘s request.

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