Low Pressure Molding

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1 Low Pressure Molding

2 2 Low Pressure Molding Low Pressure Molding 3 What is Low Pressure Molding? Low Pressure Molding is a low pressure molding process with hotmelt adhesives. It can achieve superior sealing, better protection of electrical/electronic components with higher productivity compared to those materials widely used in current sealing processes e.g. 2-component casting/potting resins or silicones. This notable process is environmentally compatible and contributes to total cost reduction due to improved productivity. Total Cost Reduction Eliminates traditional housings and cases used in potting. Saves energy by eliminating the heat curing process. Uses less adhesive for PCB encapsulation. Mold made of aluminum helps to reduce cost. Highlighted Features Low Injection Pressure Encapsulates fragile/delicate components No damage to components Injection temperature ( C) Injection Molding Low Pressure Molding Injection temp: C Injection pressure: 5-40 bar Injection pressure (bar) Application Case Sensor: 2C Casting vs. Low Pressure Molding Results after changing to Low Pressure Molding: Adhesive cost saving = 50 % Saving in production time Saving in production space Saving in component and energy costs Much better water-proof quality Adhesive Consumption/unit Current Technology 16 g / unit (Casting) Low Pressure Mold ing 4 g / unit (PA Hotmelt) Cost of Adhesive/kg X 2X Improved Productivity Adhesive Cost/unit Y Y/2 No chemical reaction: single-component material Simple and clean process Fast cycle times (10 50 seconds) Process Time 2-Component Casting Resins Hours Days Low Pressure Molding Seconds Minutes Production Cycle/unit 2 hours < 1 min Production Space Required Above data are taken from a real reference case Occupies space for case storage & curing No space for case storage nor curing Machine Maintenance Every day Once a week Superior Material Properties Process Flow Advantage of Low Pressure Molding Water-tight encapsulation with adhesion: Excellent electric insulation and water resistance Chemical resistance: Depending on their chemical basis, the molding products are resistant to gasoline, oils, alcohols, acids and alkalis Excellent thermal durability characteristics: Thermal cycle resistance, cold resistance, temperature resistance (from -40 C to +150 C) Moldability: Flexible and miniaturized product design Low flammability: UL94 V-0 available Effective strain relief Traditional Casting/Potting Process Flow Mold Case Encapsulate Palletize Setting or Vacuum Insert Electronics Cure Preheat Test Based on non-toxic and renewable raw materials: Environmentally compatible Low Pressure Molding Process Flow Insert Electronics Overmold Test

3 4 Low Pressure Molding Low Pressure Molding 5 What is Low Pressure Molding? Types of Low Pressure Molding Materials Polyamide Polyolefin Product Macromelt OM Macromelt Q Low Pressure Molding Applications Automotive Electronics Low Pressure Molding can be applied to various automotive electronic systems and devices, such as tire pressure monitoring systems (TPMS), PCBs for seat occupant sensors, belt lock sensors, ECUs for motorcycles, air quality sensors, antennas for RF devices, smart entry (E-Key) systems, etc. Service Temp ( C) -40 to to +100 Molding Temp ( C) +180 to to +200 Viscosity range (mpa.s ) 1,000 to 7,000 5,000 to 15,000 Shore Hardness A80 to D50 A60 to A90 Outstanding Properties Superior adhesion to plastics e.g. ABS, PBT, PVC Superior adhesion to PP, PE, PET UL 94 V0 V2 1. Water-tight connector 2. Micro-switch Three Main Application Groups of Low Pressure Molding Products Electronic component encapsulation It is the low pressure applied during the molding process that prevents damage to the sensitive electronic components and elements. The molding protects the electronics from external influences (moisture, mechanical stressing, etc.) and is capable of serving as a housing. Connector potting Hotmelts are used for sealing the plug and also for cable strain relief. 3. Absolute angle sensor 4. Intelligent battery sensor Grommet injection molded in place The molding process can be used to mold grommets in place. This eliminates the time-consuming process of slipping the grommet on, which can cause repetitive strain injury. The molding can also include strain relief, which also enhances its esthetics. 5. Air quality sensor 6. Temperature sensor

4 6 Low Pressure Molding Low Pressure Molding 7 Low Pressure Molding Applications Automotive Electronics PCB Overmolding 7. Other kinds of sensors 8. Antenna coil 9. GND terminal Grommets / Sockets Mobile Phone Applications Low Pressure Molding can be applied to the mobile phone battery, antenna, strobe flash, and other delicate components that require water-tightness, protection or encapsulation. Molded connectors / Sensors with water-tightness & strain relief Mobile phone battery

5 8 Low Pressure Molding Low Pressure Molding 9 Molding Machine & Mold Set Supply Molding Product Customer Supply System Mold Set Aluminum can be used as the material for making the mold set for Low Pressure Molding due to Lower injection pressure of the process Better thermal conductivity of aluminum No abrasive ingredients, e.g. fillers, glass fibers, contained in hotmelt Steel can also be used as the material for the mold set. If the component to be over-molded has steel or hard glass filled components, it is recommended to have steel inserts in this area of the cavity. Hotmelt Adhesives Technical Support Molding Machines Mold Sets Molding Machines There are many types of molding machines available: For small-scale production with manually opened mold set. For production that needs higher productivity and output, with a sliding stage or rotary table for the mold set. Further details about molding machines are available from our machine partners in each country. Supply Melting Unit Melting Unit Supplier The molding system consists of the molding product, the mold set, the machine, and the melting unit. The melting unit for the hotmelt is usually used for injection of the hotmelt adhesive into the mold set at lower pressure compared to conventional injection molding machines. The mold set, which is usually made from aluminum, facilitates the process to trial stage as it is lower in cost compared to conventional ones. System Solution Henkel supports customers throughout project development, from initial sample-making with a trial mold set to consultancy on designing complete packages for mass production based on long experience with this low pressure molding technology. Select right hotmelt Prototyping Evaluation by customer Prepare for production Project completion Check requirements Spot test, if required Develop new product Trial with mold set Produce molded samples for eval uation Environmental resistance Chemical resistance etc. Check requirements Decide right specification Supply hotmelt and machines Start production

6 10 Low Pressure Molding Low Pressure Molding 11 Technical Information Product Range for Low Pressure Molding Macromelt products are thermoplastic hotmelt adhesives based on natural fatty acids. They show good adhesion to plastics like PA 6.6, ABS and PVC, low temperature flexibility, a wide service temperature range, and superior molding properties. Technomelt Polyamid Hotmelt Technomelt Hotmelt Properties Product Test Method PA 653 PA 658 PA 6208 PA 6208 PA 633 PA 638 PA 646 PA 648 PA 676 Polyolefin Transparent Product Test Method AS 5375 AS 5361* AS 4226* Colour - Service Temp Range ( C) Amber Black Amber Black Amber Black Black Black Black to to to to to to +140 Softening Point ( C) ASTM E Viscosity at +210 C (mpa.s) ASTM D3236 4,500 3,000 3,500 7,000 7,300 7,500 Shore Hardness ISO 868 / 15s A77 A82 A90 A92 A93 A89 Creep Resistance ( C) Henkel Method MH Cold Flexibility ( C) ASTM D Special Properties Adhesion Properties Substrate good hydrolyse resistance RTI-Value for 6208 S: 95 C, UL-V0 UL-V0 UL-V0 UV-stablelized Very good cold flexibility, very good temp resistance PA6.6 good good moderate moderate moderate moderate PVC good good good excellent moderate moderate ABS good good moderate moderate moderate moderate Old names Macromelt OM XXX New Names Technomelt PA XXX A variety of adhesive values spot tests, peel strength, shear strength are available on request or can be supplied after testing by our technical customer service team. Electrical Properties: Volume Resistivity DIN IEC ~ Ω cm Dielectric Strength DIN IEC ~ 20 kv / mm The electrical values of OM648 and OM730 are not available. The data above is based on our knowledge and experience. Due to different materials and conditions of application which are beyond our knowledge and control we strongly recommend carrying out sufficient tests and consulting of our technical customer service. Except for willful acts any liability based on such recommendations or any oral advice is hereby expressly excluded. Properties Colour - white light-beige white light-beige transparent, colourless, clear Service Temp Range ( C) to to to +85 Softening Point ( C) ASTM E Viscosity at +210 C (mpa.s) ASTM D3236 2,400 4,000 45,000 Shore Hardness ISO 868 / 15s A50 A68 D45 Creep Resistance ( C) Henkel Method MH Special Properties Adhesion Properties Substrate Old names: Macromelt Q new names Technomelt AS * Development Product properties could change Broad adhesion range Broad adhesion range, UL-V2 Transmission rate at 2 mm thickness: Transmission Wavelength: rate: 450 nm 89,0 % 600 nm 90.5 % 800 nm 91,0 % 850 nm 91,5 % PA6.6 good good moderate PE good good - PP excellent excellent - ABS good good - PVC moderate moderate good PC moderate moderate good

7 _AG_ Austria Henkel Central Eastern Europe GmbH Erdbergstraße Wien Tel: Fax: Belgium Henkel Belgium n.v. Havenlaan Brussel Tel Fax Denmark Henkel Norden AB, Copenhagen Helgeshøj alle Tåstrup Tel Fax Finland Henkel Norden Oy ÄYRITIE 12 A VANTAA PUH FAX France Henkel Technologies France S.A.S. Arlington Square PE du Val d Europe 8, Bld Michael Faraday Serris MARNE LA VALLEE Cedex 4 Tél Fax Germany Henkel AG & Co. KGaA Standort München Gutenbergstraße Garching Tel Fax Italy Henkel Italia S.p.A. Via Amoretti Milano Tel Fax Netherlands Henkel Nederland B.V. Postbus CM Nieuwegein Brugwal NZ Nieuwegein Tel Fax Spain / Portugal Henkel Ibérica, S.A. C/ Córcega, n.º Barcelona Tel.: Fax: Sweden Henkel Norden AB Box Stockholm Tel.: Fax: Switzerland Henkel & Cie AG Division Loctite Salinenstraße Pratteln 1 Tel Fax United Kingdom Henkel Limited Wood Lane End Hemel Hempstead Hertfordshire HP2 4RQ Tel Fax The data contained herein are intended as reference only. Please contact Henkel Technical Support Group for assistance and recommendation on specifications for these products. designates a trademark of Henkel AG & Co. KGaA or its affiliates, registered in Germany and elsewhere Henkel AG & Co. KGaA, 2013