About the material...
Epoxy powder coating is a free-flowing, thermosetting dry powder. Think of this process as a way of "melting" paint over a copper or plated copper surface to create a durable, protective surface with thickness ranging from of 6 to 120 mils or .006 to .120 inches. When the epoxy powder cures, a cross-link occurs increasing molecular weight and insulation capability.
Insulation. Insulation. Insulation...
Epoxy powder is chemical resistant and one of the oldest powder paints used in the electronics industry. It not only protects against corrosion but carries a high manufacturers insulation rating of 800 volts per mil (.001 inches) at a minimum of 10 mil (.010 inches). Due to safety consideration it is recommended that a High-Pot test is preformed rather than rely on film thickness.
Tensile strength on raw and plated copper bar is in the range of 7500 PSI. UL rating is 130 Cº. Epoxy powder coating's high dielectric strength can be varied based on the application process and component preparation.
Storm Copper offers the following standard colors for quick pricing and delivery.
Spray Coatings: Blue, Gray, Red and Black. (Green available soon.)
Fluid Bed Coatings: Red and Black. (More available soon.)
Storm Copper conducts four component preparation processes prior to applying the powder coating:
Cleaning - Storm's bare or plated copper bar has already gone through a vigorous multi-step cleaning cycle. Yet we conduct a final cleaning process prior to coating to remove all contaminants.
Edge Conditioning - Finished edges and burr removal promote uniform epoxy powder coating for consistent dielectric strength, and may include hand sanding, small part tumbling, and if required, a machined radius.
Masking - Surfaces that do not require powder coating are masked with high temperature tape. Masking is applied to each location and remains on the part until after the curing cycle. Location of the mask is a manual operation, and a liberal tolerance is recommended. If location is critical, a line will be scribed on the conductor for more precise positioning.
Pre-Heating - Storm preheats bus bars and other copper parts to enable the epoxy powder to melt, creating a sticky film that picks up more powder, quickly and evenly.