Epoxy Coating Powders

Durable Epoxy Coating Powders that provide Electrical Insulation and Mechanical Protection


Epoxy Coating Powders

Epoxy coating powders (ECP) are often called "functional" coating powders because they serve a much larger purpose than simply a decorative coating with corrosion protection. Also called fusion-bonded epoxy (FBE) powder, they differ from other powder coatings because of the high level of functional fillers that give ECPs their electrical and mechanical properties. The most important property for these functional epoxy coating powders is electrical insulation. The temperature and environmental conditions under which electrical insulation is provided define the unique applications for which epoxy coating powders are so well suited.

Fusion-bonded epoxy coating powders are used in a wide range of applications including motor armature slot insulation, busbar & power distribution insulation, passive component coating and many more. Wherever metal or ceramic parts require electrical insulation and mechanical protection, epoxy coating powders have found a use.

Though powders for epoxy coating are available in black, they are also made in a wide range of colors including blue, red, green, beige, yellow to name a few. In fact, however, colors can be made in any color imaginable and can even be custom-colored and formulated.

CAPLINQ offers a range of functional epoxy coating powders for specific market and industrial end-use applications. Though the scope of the applications can be broad, CAPLINQ is very focused in the markets in which it competes, and as such is a market leader in each of the markets it competes in.

Please continue to our Learn More section to learn more about what where epoxy mold compounds originated, what kind of applications use ECPs and how CAPLINQ can help you to select and order the epoxy coating powtder is right for your application.

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Frequently Asked Questions

Frequently Asked Questions about Epoxy Coating Powders

What's the difference between fusion bonded epoxy powder and epoxy coating powder?

In a word: Nothing. The term fusion bonded epoxy coating powder or fusion-bond epoxy coating powder, abbreviated as FBE is often reserved for applications such as concrete reinforcement bars (rebars), pipe-coating or valve coating.

The name epoxy coating powders, on the other hand, are more common in the electronics, automotive and power distribution industries for passive component coating, motor iron armature insulation, and busbar coating. Both are thermoset plastic epoxy coatings.

How can epoxy coating powder be applied?

There are several methods for applying epoxy coating powder. Parts can be coated using a fluidized bed, sprayed with an electrostatic gun or applied using an electrostatic fluidized bed. Each method has its advantages and disadvantages.

How much insulation can be achieved using epoxy coating powder?

Epoxy coating powder can insulate parts as low as 1.5 volts and as high as 50,000 volts. Low voltages (traditionally defined as less than 600V) can be coated with very thin layers of epoxy. Medium voltages (defined as up to 38,000 volts) require high dielectric strength epoxy and thicker coating layers.

How thick can we coat using epoxy coating powder?

Coating thickness depends on the application method used. Using electrostatic coat only, the maximum thickness you could spray is approximately 250 microns. Depending on the epoxy type, this could insulate up to approximately 1000 volts. If the parts are preheated before electrostatically spraying, you could achieve up to 1200 micron thickness which could insulate up to approximately 12,000 volts.

Using a fluidized bed and preheated parts with multiple dips, you can easily coat to 4mm (4000 microns) and could insulate medium voltage busbars up to 40,000 volts. With special epoxy coating powders, it is possible to build as thick as 5mm and achieve insulation up to 50,000 volts.

What is the difference between the various formulations of epoxy molding compounds?

Epoxy coating powders' basic function is to provide electrical insulation and mechanical protection. The difference between the formulations has mostly to do with the applications for with they are designed and their application methods.

Application types require more or less of each electrical insulation and mechanical properties and the rest of the properties are designed to be optimized for electrostatic spray, fluidized bed or electrostatic fluidized bed applications methods.

Are there known brand names that use epoxy coating powder?

We have a relationship with Nordson, who make a range of electrostatic powder coating equipment. We have been successful implementing solutions with Nordson and are proud to recommend their equipment.

We also have experience with GAT finishing systems who make very complete epoxy powder coating rooms.

How do I prevent bubbles from forming after coating?

Parts must be very clean beforehand (no oil, fingerprints, etc.) and the powder should be sprayed at room temperature. Running a Design of Experiment to find the the best temperature and time to preheat and post cure materials is always recommended.

Can I make my own fluidized-bed for epoxy coating powder?

Yes you can, it is not very complicated at all. You simply need a design that allows you to pass clean compressed air through a porous membrane or fluidizing sheets. Two references are Genpore Fluidizing Sheets and Porex's porous membranes. We have designs that we can offer you.

Learn More

Busbar coating guidelines

Epoxy Coating Powders: Their origins all stem from Hysol DK18-05

Motor iron slot insulation, switchgear, capacitors, toroid cores, busbars, thermistors, varistors, and resistors: What do they all have in common? They are all applications that use epoxy coating powder for insulation and protection.

Epoxy coating powder has been around since the 1950’s. Hysol (which derived its name from "High Solids" epoxies) introduced epoxy coating powder to the world with DK18-05. It was a plastic composite with world class adhesion, toughness, strength and insulation, and the market for it grew and grew.

Motor Iron Slot insulation. Switchgear, Network Connector, and Busbar coating powder. Thermistors, Varistors, and Resistors. What do they all have in common? They are all applications that use epoxy coating powder for insulation and protection

Every epoxy coating powder company has their own version of DK18-05 in their product portfolio.

Since then DK18-05 has been copied, adapted, and further developed by a multitude of competitors. Since the 1950’s the variety of epoxy coating powders that are available is mind-blowing. Each developed and perfected for a particular application in mind.

All epoxy powder coatings are applied electrostatically to metal parts usually in a fluidized bed or with a blow gun

All epoxy powder coatings are applied electrostatically to metal parts usually in a fluidized bed or with a blow gun. A fluidized bed is better for high quantities and larger components. Electrostatic spray guns are better for lower quantities of perhaps more complicated components.

In both cases the powder is given an electrostatic charge which makes it cling to earthed components which have an opposite charge. A little like how a balloon will stick to wool. This process ensures a uniform evenly applied layer: eliminating over or under coating and unnecessary texture. The part is then heated in a kiln, oven, or induction heater where the powder coating melts and finally cures.

Epoxy Coating Powder: a composite material with variable formulations and properties!

The cure time, hot plate gel time, and glass temperature, as well as its final cured characteristics depend on the type of epoxy resin, hardener, fillers, and additives used to create that particular epoxy coating powder.

Important characteristics to bear in mind when selecting a coating is powder are thermal conductivity, how thin or thick it can be applied, as well as how compatible it is with your equipment, and finally the regulations of the countries where it will be made and used in the end product.

It isn't the 1950's anymore the world has changed and so have Epoxy Coating Powders!

It isn't the 1950's anymore. The world has changed and so have Epoxy Coating Powders!

If we take DK18-05 as an example we can see why it’s been one of the most successful epoxy coating powders. What made it so popular? DK18-05 is perfect for tantalum capacitors that need a low cure temperature. It’s also extremely thermal shock resistant: surviving thermal cycles of -125C to +125C. This makes it highly relevant for ceramic capacitors. It also comes in a great set of colors: blue, gold, green, and black.

But the world is a changing place and the golden days of DK18-05 are over. It’s no longer acceptable to use Halogens, which Dk18-05 is full of. Recently the EU added TMA to its list of Substances of Very High Concern (SVHC): making DK18-05 and its many copies no longer suitable for the European Market.

There is also a new trend in Tantalum capacitors to use polymer capacitors. Polymer capacitors need even lower cure temperatures that DK18-05 can provide, making it now irrelevant. Ceramic capacitors are getting bigger and DK18-05 is too brittle to meet the specifications for these larger Class 1 ceramic capacitors.

Selecting the right Epoxy Coating Powder for the world of today

So if your searching for a new generation epoxy coating powder that is ready for the requirements of today CAPLINQ is here help. Whether you’re concerned about Pick-up temperature or Glass transition temperature CAPLINQ can help inform and guide you. At CAPLINQ we have to expertise to guide you in your epoxy coating powder product choice, adjust formulations to suit you, or create altogether completely new custom epoxy coating powder formulation together with you.

Epoxy Coating Powders for Busbar Coating, Switchgear Equipment and High Voltage Fuses

For many years CAPLINQ has supplied a range of epoxy coating powders developed for medium voltage (600V – 38,000V) bus bar and switch gear applications. CAPLINQ is one of the few epoxy coating powder manufacturers with "switch panel-rated" material, meaning that their epoxy coating powders are qualified for use in Power Distribution Switch Boards. Given the critical nature of the application, the time and costs involved to pass UL-certification, major Power Management Companies reply on CAPLINQ and their family of UL-listed epoxy coating powders. All the products offered by CAPLINQ for busbar applications are UL-listed.

Epoxy Coating Powder for Busbars
Epoxy Coating Powder for Slot Insulation of Motor Armature

Epoxy Coating Powders for Slot Insulation of Motor Iron Armatures and Stators

CAPLINQ supplies a range of epoxy coating powders developed for motor iron armatures. From incredible bed life epoxy powders to high productivity coating powders to Class H-rated coating powders, CAPLINQ has an epoxy coating powder to meet every type of motor armature insulation application. All the products offered by CAPLINQ for motor iron armature applications are UL-listed.

Epoxy Coating Powders for Resistors, Capacitors, Varistors and Passive Electronics

CAPLINQ supplies a range of epoxy coating powders developed for electrical insulation of passive electronic devices including resistors, varistors and capacitors. From incredible thermal cycle materials for Class 1 rated Ceramic Capacitors, to low cost epoxy coating powders for film wrap capacitors, CAPLINQ products pioneered this industry and continue to push the envelope for the best performing materials on the market today. Most of the products offered by CAPLINQ for passive electronics have a UL-listing.

Epoxy Coating Powder for Capacitors, Varistors, Resistors
Epoxy Coating Powder for Toroids, Magnetic and Powder Cores

Epoxy Coating Powders for Toroids, Magnetic and Powder Cores

CAPLINQ supplies a range of epoxy coating powders developed for toroids, magnetic cores and powder cores. These products are low shrinkage and low moisture absorption coating powders which maintains the stability and inductance values of the toroid cores. These products are suitable for Molypermalloy (MPP), Iron, Sendust and other alloy powder cores. Most of the products offered by CAPLINQ for powder cores have a UL-listing.

Epoxy Coating Powders as Epoxy Binder Resin for Pot Cores

CAPLINQ supplies epoxy coating powders developed specifically to act as an epoxy binder resin for pot cores used in inductor motors. These products have excellent green strength to allow the transport from the press to the oven. Once cured, these pot cores can be used at temperatures up to 180°C and maintain their mechanical properties as well as their magnetic properties.

Epoxy Binder Resin for Pot Cores

Epoxy Coating Powder for Motor Iron Armature Insulation

CAPLINQ offers a range of epoxy coating powders for slot insulation including blue, black and green variants and Class H candidates.

Epoxy Coating Powder for Motor Iron Armatures Slot Insulation Blue Black Green

Technical Papers & Brochures

CAPLINQ offers a wealth of Technical Papers, Marketing Brochures, Technical Data Sheets and SDS covering our Epoxy Coating Powders.

Read our Blog on Epoxy Coating Powders

We try to post as much information as we can on our blogs, to help you find more relevant information about how to select, use and apply epoxy coating powders.

Epoxy Coating Powders for Busbar Insulation

CAPLINQ offers a range of epoxy coating powders for busbar and power distribution insulation.

Epoxy Coating Powder Busbar Insulation Beige