Dielectric body for an electrical component
A method of assembling an electrical component is provided. The method includes providing a dielectric body configured to support an electrical conductor. The dielectric body includes a polymer resin. The dielectric body includes glass filler elements embedded in the polymer resin, and the dielectric body includes gas cells embedded in the polymer resin.
1 . A method of assembling an electrical component, the method comprising:
providing a dielectric body configured to support an electrical conductor, the dielectric body including a polymer resin, the dielectric body including glass filler elements embedded in the polymer resin, and the dielectric body including gas cells embedded in the polymer resin, wherein the dielectric body has a two-stage dielectric constant reduction with a first stage reduction from embedding the glass filler elements in the polymer resin and a second stage reduction from embedding the gas cells in the polymer resin.
2 . The method of claim 1 , further comprising providing the electrical conductor at least one of on or in the dielectric body.
3 . The method of claim 1 , wherein the glass filler elements are gas filled glass filler elements.
4 . The method of claim 1 , wherein the gas cells attach to the glass filler elements in the polymer resin.
5 . The method of claim 1 , wherein the glass filler elements form nucleation sites for the gas cells to evenly distribute the gas cells throughout the polymer resin.
6 . The method of claim 1 , wherein the gas cells are provided in the dielectric body by a foaming process.
7 . The method of claim 1 , wherein the gas cells are provided in the dielectric body using a chemical foaming agent.
8 . The method of claim 1 , wherein the gas cells are provided in the dielectric body using a physical foaming agent.
9 . The method of claim 1 , wherein said providing the dielectric body comprises injection molding the dielectric body.
10 . The method of claim 1 , wherein said providing the dielectric body comprises extruding the dielectric body.
11 . The method of claim 1 , further comprising forming a conductor channel in the dielectric body.
12 . The method of claim 11 , further comprising positioning an electrical conductor in the conductor channel.
13 . The method of claim 1 , wherein the glass filler elements occupy at least 5% of a volume of the dielectric body and the gas cells occupy at least 5% of the volume of the dielectric body.
14 . A dielectric body for an electrical component, the dielectric body comprising: a polymer resin; glass filler elements embedded in the polymer resin; and gas cells embedded in the polymer resin between the glass filler elements, wherein the gas cells are attached to the glass filler elements in the polymer resin.
15 . The dielectric body of claim 14 , wherein the glass filler elements are gas filled glass filler elements.
16 . The dielectric body of claim 14 , wherein the gas cells form a foamed cellular structure in the dielectric body.
17 . The dielectric body of claim 14 , wherein the dielectric body includes a conductor channel in the dielectric body configured to support an electrical conductor in the conductor channel.
18 . The dielectric body of claim 14 , wherein the glass filler elements occupying at least 5% of a volume of the dielectric body and the gas cells occupy at least 5% of the volume of the dielectric body.
19 . The dielectric body of claim 14 , wherein the dielectric body has a two-stage dielectric constant reduction with a first stage reduction from the glass filler elements embedded in the polymer resin and a second stage reduction from the gas cells embedded in the polymer resin.
20 . The dielectric body of claim 14 , wherein the glass filler elements form nucleation sites for the gas cells to evenly distribute the gas cells throughout the polymer resin.
21 . An electrical component comprising:
a substrate including a dielectric body, the dielectric body including a polymer resin, the dielectric body including glass filler elements embedded in the polymer resin, and the dielectric body including gas cells embedded in the polymer resin, wherein the glass filler elements form nucleation sites for the gas cells to evenly distribute the gas cells throughout the polymer resin; and
an electrical conductor held by the substrate and at least partially surrounded by the dielectric body.
22 . The electrical component of claim 21 , wherein the dielectric body has a two-stage dielectric constant reduction with a first stage reduction from the glass filler elements embedded in the polymer resin and a second stage reduction from the gas cells embedded in the polymer resin.