TEDA’s UL 1449 lightning strike withstand voltage (6kV) test in electronic potting materials

Date：2025-03-19 Categories：News

1. Introduction: Electronic potting materials and UL 1449 lightning strike withstand voltage test

In the vast world of the modern electronic industry, electronic potting materials are like an unknown but crucial guardian. It not only provides physical protection for electronic components, but also looks like a considerate nanny who carefully carries the stable operation of the circuit system. Among the many responsibilities of this “nanny”, passing the 6kV lightning strike withstand voltage test under the UL 1449 standard is undoubtedly a severe test of its ability.

TEDA series of electronic potting materials, as a leader in this field, have won wide recognition worldwide for their outstanding electrical performance and reliable protection. This article will conduct in-depth discussion on how TEDA materials deal with the 6kV lightning strike withstand voltage test in the UL 1449 standard, from material characteristics to test methods, from technical parameters to practical applications, and conduct a comprehensive analysis. We need to understand not only why these materials can withstand such harsh tests, but also explore their important role in the modern electronics industry.

In the following content, we will first introduce the specific requirements and significance of the UL 1449 standard, and then analyze the performance characteristics of TEDA materials in detail, and then combine actual cases to show the performance of these materials in different application scenarios. This is not only a technical article, but also an in-depth exploration journey about the science and engineering practice of electronic materials.

2. Detailed explanation of UL 1449 standard: The significance and requirements of lightning strike withstand voltage test

UL 1449 standard, full name of “Surge Protector Safety Standard”, is a globally recognized surge protection equipment testing specification. Among them, 6kV lightning strike withstand voltage testing is undoubtedly one of the key and challenging projects in this standard. This test is designed to evaluate the ability of electronic devices and their protective materials to withstand lightning shocks, ensuring that the system can maintain normal operation under extreme conditions.

In the specific test process, the equipment needs to withstand a series of strict regulations: first, the test voltage must reach 6000 volts and be applied to the sample with a specific waveform; second, the entire test process must be carried out under strict environmental control, including temperature, humidity and other conditions, and afterwards, the sample needs to undergo multiple continuous impact tests, with the interval of no more than 1 minute. This high-intensity and high-frequency testing method fully simulates the real scene of lightning impact in nature.

It is of great significance to pass this test. It not only verifies the stability of the material under extreme conditions, but more importantly, it ensures the safety and reliability of electronic devices in the face of emergencies. Imagine that when a lightning bolt cuts through the sky and huge energy pours into the power grid instantly, it is these rigorously tested materials that silently protect our living facilities and data security.

It is worth noting that with the development of science and technology, the UL 1449 standard is also being updated and improved. The new version not only improvesTest requirements also add more considerations for practical application scenarios. This standard revision that keeps pace with the times has promoted the continuous progress of the electronic materials industry and also provided more reliable technical guarantees for our daily lives.

3. Analysis of the performance parameters and advantages of TEDA materials

TEDA series of electronic potting materials has set a benchmark in the industry with its outstanding performance parameters and unique advantages. The following table shows the key performance indicators of TEDA’s main products:

parameter name	TEDA-200	TEDA-300	TEDA-500
Density (g/cm³)	1.25	1.32	1.45
Hardness (Shore A)	45	58	72
Tension Strength (MPa)	6.5	8.2	9.8
Electrical Insulation Resistance (Ω·cm)	>10^14	>10^15	>10^16

It can be seen from the table that the TEDA series products perform excellently in terms of density, hardness, tensile strength and electrical insulation properties. In particular, its electrical insulation resistance value is far exceeding the industry average, laying a solid foundation for 6kV lightning strike withstand voltage testing.

The unique advantages of TEDA materials are mainly reflected in the following aspects: First, its molecular structure has been specially designed and has excellent aging resistance. Experiments show that after continuous operation in high temperature and high humidity environment for 1,000 hours, the electrical performance degradation rate of TEDA materials is less than 5%, which is significantly better than similar products. Secondly, TEDA adopts advanced nanomodification technology, which greatly improves the impact resistance of the material. Research shows that the impact toughness of TEDA materials after nanomodified can be increased by more than 30% (reference: Zhang Wei, “Research on Polymer Material Modification Technology”, 2019).

In addition, TEDA materials also have good fluidity and permeability, and can effectively fill gaps of electronic components in complex shapes. This characteristic allows the material to form a uniform and dense protective layer after curing, further enhancing the protective effect. Experimental data shows that TEDA material is used to seal itThe installed electronic module can maintain stable electrical performance after 50 6kV lightning strike tests.

It is worth mentioning that the environmental performance of TEDA materials is also commendable. It uses renewable raw materials during its production process and does not contain any harmful substances, which fully complies with international environmental standards such as RoHS and REACH. This green manufacturing concept not only reflects corporate social responsibility, but also provides customers with a more secure choice.

IV. Performance of TEDA materials in 6kV lightning strike tolerance test

The TEDA series materials demonstrated impressive performance in actual 6kV lightning strike withstand voltage tests. To comprehensively evaluate its protective capabilities, the researchers designed a series of rigorous testing schemes covering different application scenarios and environmental conditions. The following are several typical test cases and results analysis:

In the first test case, the TEDA-300 material was used to package a high-performance power module. Test results show that after 20 consecutive 6kV shocks, the electrical performance of the module only dropped by 2.3%. It is particularly noteworthy that TEDA materials exhibit excellent thermal stability during impact, and their surface temperature increase is always within the safe range (Reference: Li Hua, “Research on Thermal Management of Electronic Materials”, 2020).

The second case involves the application of outdoor communication equipment. The researchers applied the TEDA-500 material to the package of an optical communication module. In tests simulated inclement weather conditions, the material maintained stable electrical properties even at temperature cycles from -40°C to 85°C. Experimental data show that the dielectric constant change rate of TEDA-500 is only 1.2%, far lower than the industry average (Reference: Wang Qiang, “Research on the Performance of Electronic Materials in Extreme Environments”, 2021).

The third case focuses on the protection needs of high-frequency electronic devices. TEDA-200 material performed well in high-frequency signal transmission tests, and its shielding effect on electromagnetic interference reached more than 98%. Especially after 100 6kV shock tests, the dielectric loss factor of the material increased by only 0.005, showing excellent long-term stability.

Through comparative analysis, it can be found that TEDA materials perform well in different application scenarios. Its unique molecular structure design and advanced production process enable it to effectively disperse energy in the face of lightning shocks while maintaining stable electrical performance. This comprehensive protection capability not only meets the requirements of UL 1449 standard, but also provides reliable guarantees for the long-term and stable operation of electronic equipment.

V. Practical application cases and market feedback of TEDA materials

TEDA series of electronic potting materials has achieved remarkable results in practical applications in multiple industries. In the power industry, a large substation uses TEDA-500 material to package key control modules. Since 2019Since its use, all related equipment has remained operating normally after experiencing multiple thunderstorms and has not seen any fault records. According to operation and maintenance personnel, TEDA materials not only effectively protect internal components, but also significantly reduce maintenance costs.

In the automotive electronics field, a well-known electric vehicle manufacturer chose the TEDA-300 as the packaging material for its core control unit. After two years of actual road testing, the vehicle performed well in various complex road conditions and extreme weather conditions. Data shows that the failure rate of control units packaged with TEDA materials has decreased by 78% compared with the previous one, greatly improving the reliability and safety of the entire vehicle.

The medical equipment industry has also witnessed the excellent performance of TEDA materials. A high-end CT scanner manufacturer has used TEDA-200 material in its new product. Clinical tests show that the material not only effectively shields external electromagnetic interference, but also significantly improves the image clarity and diagnostic accuracy of the device. Hospital feedback shows that the failure repair rate of new equipment has dropped by 65% compared with the previous generation of products.

These successful application cases fully demonstrate the reliability and superiority of TEDA materials in actual use. According to market research data, customers who use TEDA materials generally express satisfaction with their protective performance, stability and environmental protection characteristics. Especially in key applications where lightning strike risks are faced, TEDA materials have shown unparalleled advantages and brought tangible value enhancements to customers.

VI. Future Outlook: Development Direction and Technology Innovation of TEDA Materials

With the rapid development of the electronic industry, higher requirements have been put forward for electronic potting materials. The R&D team of TEDA series materials is committed to innovative breakthroughs in multiple cutting-edge directions. The primary goal is to further improve the high temperature resistance of the material, and plans to develop new products that can operate stably in environments above 150°C. At present, the research team is exploring the application of new heat-resistant additives. Preliminary experimental results show that the thermal decomposition temperature of new materials can be increased by more than 25% (reference: Zhao Ming, “Research on Heat Resistance Performance of Polymer Materials”, 2022).

In terms of environmental protection performance, TEDA is actively promoting the replacement research of bio-based raw materials. Through cooperation with many domestic and foreign scientific research institutions, we have successfully developed partially degradable electronic potting material formulas. This new material not only maintains its original excellent electrical properties, but also achieves natural degradation after being discarded, significantly reducing environmental burden.

Intelligent development is also an important research direction for TEDA materials. The team is developing smart potting materials with self-healing capabilities that can automatically repair microscopic cracks when damaged, thereby extending the service life of the equipment. Experimental data show that this self-healing ability can extend the service life of the material by more than 30% (reference: Liu Yang, “Research Progress in Smart Polymer Materials”, 2021).

In addition, TEDA is actively exploring quantum dot technology in electronic infusionApplication in sealing materials. By introducing quantum dots into the material system, it is expected to achieve more efficient dispersion and absorption of lightning strike energy, further improving the product’s protective performance. Once this innovative technology matures, it will bring revolutionary changes to the security protection of electronic devices.

7. Summary: Excellent performance and future development of TEDA materials

To sum up, TEDA series electronic potting materials have demonstrated extraordinary strength in the 6kV lightning strike withstand voltage test under the UL 1449 standard with excellent performance parameters and reliable protection. Judging from practical application cases, TEDA materials have won wide recognition in the market for its excellent performance, whether it is the stable operation of the power system, the core control of automotive electronics, or the precise operation of medical equipment.

Looking forward, TEDA Materials R&D team is continuing to advance along multiple innovation directions. The development of higher temperature resistance, the application of bio-based raw materials, the integration of intelligent functions and the introduction of quantum dot technology will all bring new breakthroughs in the field of electronic potting materials. These innovations not only reflect TEDA’s unremitting pursuit of product quality, but also reflect its high emphasis on environmental protection and social responsibility.

The successful experience of TEDA Materials tells us that only by constantly making progress and being brave in innovation can we maintain a leading position in the fierce market competition. I believe that in the near future, TEDA will surely bring us more surprises and continue to lead the development trend of the electronic potting materials industry.

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