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

SMA Solar Tech­nol­o­gy AG, 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, SMA Solar Tech­nol­o­gy 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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