July 13, 1954 METHOD OF R.

CASTING
E. CUNNINGHAM
ELECTRICAL DEVICES AND
2,683,766
ARTICLE PRODUCED THEREBY
Filed Aug. lo, 948

NZASA
21.222
Scessee

Fig. 2 rvivorvitov
Aussell. EDWARD CUWWGHAM

Attorney
 Paterated July 13, 1954
2,683,766

UNITED STATES PATENT OFFICE

2,683,766
METHOD OF CASTENG ELECTRICAL DEVICE
AND ARTICLE PROBUCED THEREBY
Russeli Edward Cunilingian, Washington, D. C.,
assignor to Melpar, Igae., Alexandria, Wa.
Application August 10, 1948, Serial No. 43,43
6 Claims. (C. 174-52)
This invention relates broadly to the potting
2
within a casting of resinous plastic material, of The present invention involves the coating of
electrical components generally, and particularly the Vacuu... tubes, or other electrical coraponsents,
to the potting of fragile electrical components, with a resilient plastic, which may be formulated
such as miniature vacuum tubes and the like, 5 and With standard heat stabilizers and plasticizers,
for the purpose of protecting the latter against which has the resilience requisite to enable
the coating to absorb the stresses generated by
mechanical shock, moisture, fungus and various the Contraction of the inain potting corpound
other effects deleterious to the life and proper during polymerization and cooling of the latter,
functioning of the electrical components. and which is essentially capable of forming a bond
Broadly described, the present invention in 10 With the resinous casting.
volves potting of electrical components, Such as it is the primary virtue of the present inven
electronic vacuum tubes, metallic bodies, or the tion that the coating of the electrical coponents
like, in polyester resin or other resins which are Inay be accomplished by a simple dipping process
shock proof, rigid, and relatively non-hyglo Which requires very little time to accomplish, and
scopic, but which have a contractibility different which has been found, in practical manufact
from that of the electrical components during ing operations, to be practically 100% effective
cooling or curing of the resinous compound. In in protecting the fragile electrical coiponents
general, it has been found that the resinous coin during potting, yet to involve substantially no
pounds utilized in fabricating a resinous cast OSSibility of dail&ging the cornponents diring
ing contract during cooling and curing, and ill the process of applying the protective coating
relation to the contraction of glass or metal, coin thereto. The initial protective coating nay, it
tract volumetrically to a diffeerint extent than Self, be made of a plastic, preferably one Winich.
the latter. This difference in contractibility is relatively resilient, and since the protective
causes mechanical damage to electrical con coating is formed in a relatively thin coating,
ponents, and especially to those which may in and is, in any event, resilient, no dainage to the
corporate glass in their structure, and in the case vacuum tubes or other electrical components re
of miniature vacuum tubes in particular, results Suit from the formation of the initial protective
in leakage of gas into the envelope of the subse, coating on the components. i.he Coated Coir
destroying the operability of the tube. In the ponents may then be inserted in the rain potting
case of metallic bodies, the contraction of the compound, which may comprise resinous mate
metal is less than that of the casting, resulting riai, or in fact, any shock proof, rigid and rela
in a defective casting rather than in dannage to tively non-hygroscopic potting coin pound, prior
the metallic bodies. to curing of the latter. The Subsequent curing
It is well known in accordance with prior art, and cooling of the potting compound Will
have no mechanical effect upon the electrical
practice, to Seal vacuum tubes or other fragile 35 components
electrical components within an envelope or con themselves, since the resiliein, pias
tainer, which may take the form of a cylinder
tic coating takes up the shrinkage of the potting
Or Sleeve, the container being formed of glass compound and does not pass on Stresses or Strains
or of a relatively resilient plastic, prior to in to the coated electrical components.
Setion of the corponents into the resinous cast 40 imore Likewise, where the potting compound contracts
ing material, in order that the covering may al slowly than the potted element during cool
sorb the StreSSes due to the contraction of the
iing, the compound Will not pull away fro tine
resinous material during casting, thus avoiding latter to for in a defective casting.
damage to the components or defects in the cast By proper choice of the composition of the
tective coating with respect to the cheriaica, ao
ing. Various difficulties are found to exist in stitution of the inain potting coin polid, poly
practice in this procedure, as applied particularly merization of the latter is not inicited at the
to rainiature vacuurn tubeS. In Sertion of the inter-face between the inlain casting aid the 'e-
vacuum tubes into the containers is accoil panied, silient plastic of the coating, whic: Seives to re
in the first place, by considerable possibility of duce stresses at or adjacent to the inter-face,
damage to the tubes, and the insertion requires and results in a Sinooth and uniforin casing,
very great care and accordingly consumes con not only in portions of the casting wig. 3,'e
siderable time. Wety often when damage has remote from the electiical components, but also
Occurred this is not ascertainable until the pot at and adjacent thereto.
ting process has been completed, so that consid The use of a protective coating fabricated of
erable economic waste is involved in proceeding 55 a plastic which is compatible With the rain pot
according to the known methods. ting compound is eSpecially in portaint in tie

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 2,683,766
3 4.
present invention. It is not feasible to utilize as whereas other types are relatively temperature in
a protective coating such substances as rubber or Sensitive. The differences in dipping process are
latex, or the like, which appear to have the required by these differences in characteristics
requisite mechanical properties, since such ma-. of the elements or units which are to be dipped.
terials, being non-compatible with the resinous In dipping temperature insensitive coin pointents
compound forming the casting, preverit polyi aeri Or unitS, the components are first cleaned and
zation of the latter Over a wide Voiurine adjacent freed of grease, and then heated to a teiperature
to the rubber or latex, or the like, producing ain in the range approximately 70° to 325 ii., de
unsatisfactory casting. pending on the thickness of the uitinate coating
It is, accordingly, a broad object of the present which is desired, the higher temperatures re
invention to provide a novel nethod for potting Sulting in a greater thickness of coating in a
fragile objects within a mass of shock proof, given dipping time. For most purposes it inas
rigid and relatively non-hygroscopic in atterial, been found that a coating having a thickness of
such as polyester resin, or the like. from 3 to 5 thousandths of an inch is adequate,
it is a more specific object of the present in and for this purpose a temperature intern ediate
vention to provide a method of potting electronic the values 70 to 325 F., say about 260' E., inay
vacuum tubes or other fragile electrical compo be ein ployed. The component, after being
nents in polyester resins, or other resins which cleaned and freed of grease and heated to the
are shock proof, rigid and relatively non-hygro indicated temperature, is dipped into the liqui
scopic, in a rapid and efficient manae)', and With 20 plastic, the latter comprising poly Vinyl chloride
Substantially no Spoilage. formulated with a Suitable plasticizer and heat
It is, more specifically, an object of the present Stabilizer, in One Specific application of the in
invention to provide, as a new article of Yaar vention, which is sold cominercially under the
facture, electric components in potted fol'in, cast trade name “Geon' 100 x 210. The coiaponsent
within a mass of resinous material, and particul 25 is permitted to reinain in the liquid plastic for
larly resinous naterial which initially exists hot the period of time necessary to enable the desired
in the liquid State, and Which is converted cy thickness of coating to be built up, after which
cooling to the solid State, Wherein the cornpo-. the component is removed from the piastic and
nents are provided with One or noire protective placed in an Owen where it is heated at a tein
layers of a resilient plastic material which is 30 perature of 350° F. for the length of time required
compatible with the material of the nain casting. for plasticization. The part inay then be e
The resilient plastic raterial absorbs stresses noved from the Owen, and when renoved is
due to contraction of the main body of the cast ready for use.
ing during cooling, in order to protect the elec In order to dip temperature sensitive parts,
trical components mechanically, and the protec 35 the use of a hot liquid plastic and the subsequent
tive coating is coinpatible cheinically with the baking process is obviously inadvisable. For dip
raain casting, So that the islain casting is SiOot ping Components of this character, the coin
and uniform in all parts theireof, including parts ponentS are first cleaned and rendered gi'ease
thereof which are at or adjacent to the inter-face free, and thereafter are dipped at room tempera
of the protective coating and the inain body of 40 ture into a Water Suspension of polyvinyl cho
the casting. ride, which is known commercially by the trade
Resinous castings constructed in accordance name “Geon Latex 31X,' and after being dipped,
with the present inventioi) are Sanooth and con is removed and permitted to dry at room ten
tinuous throughout, having no air gaps Or Spaces, perature, or at slightly higher temperature, for
particularly at the inter-face between the protec 45 2, length of time necessary for the complete evap
tive coating and the main resinous Casting, where Oration of Water from the coating. Successive
by electric leakage between the various parts of dipS may be made to build up the coating to the
the electrical coin poients when Subjected to elec desired thickness, which may be in the neighbor
trical stresses is completely obviated. hood of 3 to 5 thousandths of an inch, and after
The novel features which are characteristic 50 the Coating has been thoroughly dried the part
of my invention are set forth in the appended is ready for casting.
claims. The invention itself, however, Will best Referring Specifically to Figure of the draw
be understood by reference to the following spec ingS, there is illustrated a miniature vacuum
ification, when considered in connection with the tube having a glass envelope 2 containing vari
accompanying drawings, in Which: 55 ous electrical elements 3 which are well known
Figure 1 is a longitudinal view taken in section and commonly employed in the interior of elec
and showing a composite Structure comprising a tronic Vacuum tubes, and comprising further a
niniature electronic Vacuum tube Surroiaded plurality of leads 4 for enabling electrical con
by a cushioning coating, the latter being in turn nection with the elements 3 internally of the
Surrounded by a resinous casting; and, 60 tube. The reference numeral 5 denotes a coat
Figure 2 is a view in longitudinal Section show ing of polyvinyl chloride, resulting froin either
ing a Sub-assembly of electiical componenis, of the dipping processes which have been de
sone of which have been provided with a protec Scribed immediately above, and which has a
tive and resilient coating prior to casting within thickneSS of 3 to 5 thousandths of an inch.
a considerable in 2SS of resinous in atterial. 65 The Same dipping process inay be applied not
Two slightly different methods of dipping elec Only to electronic Vacuum tubes, but to any elec
trical components prior to casting are provided trical Component which has a co-efficient of
in accordance with the present invention. Soth contraction Substantially different from that of
methods produce essentially the Sarine result. the resinous potting compound, and particularly
However, the methods may be applied nost ad it may be applied to metallic elements having
vantageously in connection with the dipping of any appreciable size, as for example, choke coils,
different types of components. Some types of transformers and the like.
electrical components are relatively temperature In the case of electronic vacuum tubes, the
Sensitive, or Subject to damages when raised to glass envelope of the tube has substantially a
a relatively moderate temperature, say 200 F., 75 Zero co-efficient of contraction or expansion with

m
 2,683,766
5 6
heat, While the resinous potting compound con
tracts relatively sharply with cooling. Metallic
elementS, on the contrary, have a smaller co
efficient of contraction than does the potting
Compound and, accordingly, tend to separate
from the latter, introducing cracks in the pot
ting Compound which may extend entirely there
through and render the final produce pervious
to moisture, and likely to crack and break up
in response to shock.
Small relatively Soft elements such as resistors,
condensers, and the like have sufficient resilience
in and of themselves to give, under the strains
introduced by the potting process, and do not
normally require dipping.
After all the elements which are to be assem
bled on a common terminal board, as 6, Figure 2,
and Which require dipping, have been dipped and
the requisite coating formed, the wiring process ing substantially no contraction during cooling,
is completed, inter-connecting the various ele- : Within a mass of polymerized resinous casting
mentS Such as the transformer and the elec
tronic Vacuum tubes 8, 9 and le, with the various
resistOS , and the condensers 2, the entire
terminal board 6 is then inserted in a liquid
resinous compound, preferably a polyester resin,
With the requisite leads 3 brought out externally
of the casting. The entire casting is then per
Initted to cure at a slow rate, forming, eventually,
a Shock proof, rigid, non-hygroscopic covering
for the electrical components.
It has been found in actual production Work
that application of my method provides highly
effective potted electrical assemblies, which may
be produced relatively rapidly and with substan
tially no Spoilage, in contrast with the results
Which i have been able to obtain by the older
methods knoWn to me, and one of which is dis
closed in the U. S. patent to Wer Planck et al.,
#2,222,729.
The particular type of coating which I have
utilized in the practice of my product is entirely
compatible with the particular resin which I use
for the main casting, and the Casting is Smooth
and uniform throughout every element of volume
thereof to and including the inter-face between :
the coating and the casting. Accordingly, the
process results in no damage to fragile electrical
components, by reason of shrinking of the pot
ting resin nor does the potting resin pull aWay
from potted metallic element or crack, when
potting metalic elements Since the potting resin
forms a bond With the resilient coating, which
takes up Volumetric differences between the
metallic elements and the resin, introduced by
the process of cooling and curing the casting.
Upon completion of the preparation of an
article nanufactured in accordance With my
novel method, the resulting Casting is found to
be clear in color completely uniform in mechani
cal structure, and free of all Cracks and air
bubbles, and fragile electrical Components in
cluded in the casting are found to be free of
damage caused by stresses and strain introduced
by cooling and curing of the Casting.
What I claim as new and desire to Secure by
Letters Patent of the United States is:
1. An article of manufacture, comprising, a
relatively fragile electrical component, a coating
for said electrical component consisting of at
least one layer of polyvinyl chloride, said coating
completely enveloping said component and in
intimate contact therewith over the entire sur
face thereof, and a substantial quantity of poly
Inerized casting resin in an infusible solid state
encompaSSing Said coating, the characters of
Said casting resin and of said coating being such
that polymerization of said casting resin at the
interface between said resinous casting com
pound and Said coating is complete, said casting
resin being Shock-proof, rigid, relatively non
hygroscopic and having a contractibility different
fi'OIn that cf the electrical component during
Curing of the Casting resin.
s 2. The combination in accordance with claim
Wherein Said electrical component is a minia
tire Vacuum tube.
3. The method of casting a fragile body, hav
Compound having Substantial contraction during
Cooling, comprising, coating Said fragile body in
at least One layer of polyvinyl chloride drying
Said at least one layer of polyvinyl chloride, cast
ing Said fragile body coated with said polyvinyl
chloride in liquid polymerizable resinous casting
Compound, and polymerizing and solidifying said
casting compound, said casting compound hav
ing Such character in relation to said polyvinyl
chloride that polymerization of said casting com
pOlind is not prevented at the interface of said
casting compound and said coating by the poly
Vinyl chloride, said casting compound being
shock-proof, relatively non-hygroscopic and
rigid.
4. The method in accordance with claim 3
Wherein the Step of enveloping is accomplished
by dipping Said fragile body in a water Solution
of Said polyvinyl chloride at substantially room
termperature, and the Step of drying by evaporat
ing the Water from the Solution.
5. The method in accordance with claim 3,
Wherein Said coating is forined to a thickness
between 2 to iO thousandths of an inch.
6. The nethod in accordance with claim 3,
wherein said coating is formed by heating said
body to a temperature in the range 70°-325 F.,
dipping the heated fragile body in liquid poly
vinyl chloride, removing the body from the liquid
polyvinyl chloride with a coating of polyvinyl
chloride adhering thereto, and heating the body
and its coating at polymerizing temperature.
References Cited in the file of this patent
5s UNITED STATES PATENTS
Number Name Date
1497,449 Kempton ---------- June 10, 1924
1,613,758 Lindstron -------- Jan. 11, 1927
1,746,469 Grunow ----------- Feb. 11, 1930
2,184,876 Sherts ------------ Dec. 26, 1939
2,222,729 Wer Planck -------- Nov. 26, 1940
2,354,908 BinneWeg ---------- Aug. 1, 1944
2,372,208 Klumb ----------- Mar. 27, 1945
2,397,242 Chubb ------------ Mar. 26, 1946
2,431,745 Flanagan ---------- Dec. 2, 1947
FOREIGN PATENTS
Nuraber Country Date
500,298 Great Britain ------ Feb. 7, 1939