What is Macromelt Molding?

Macromelt Molding

What is Macromelt Molding? What is Macromelt Molding? Macromelt 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. What is Macromelt Molding? Highlighted Features Low Injection Pressure Encapsulates fragile/delicate components No damage to components Improved Productivity No chemical reaction: single-component material Simple and clean process Fast cycle times (10-50 seconds) Superior Material Properties 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 Injection temperature 400 350 300 250 200 150 100 50 0 Moldability 0 200 400 600 800 1000 1200 1400 Injection pressure (bar) Flexible and miniaturized product design Low flammability UL94 V-0 available Effective strain relief 2-Component Casting Resins Macromelt Molding Process Time Hours - Days Seconds - Minutes Machine Maintenance Injection Molding Macromelt Molding Injection temp: 180-240 C Injection pressure: 5-40 bar Every day Once a week 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. Application Case - Sensor: 2C Casting vs. Macromelt Molding Adhesive Consumption/unit Process Flow Advantage of Macromelt Molding Mold Case Current Technology 16g/unit (Casting) Traditional Casting/Potting Process Flow Palletize Low Pressure Macromelt Molding 4g/unit (PA Hotmelt) Cost of Adhesive/kg X 2X Adhesive Cost/unit Y Y/2 Production Cycle/unit 2 hours < 1 min Production Space Required Occupies space for case storage & curing Above data are taken from a real reference case No space for case storage nor curing Insert Electronics Results after changing to Macromelt Molding: Adhesive cost saving = 50% Saving in production time Saving in production space Saving in component and energy costs Much better water-proof quality Preheat Thermal cycle resistance, cold resistance, temperature resistance (from -40 C to +150 C) Based on non-toxic and renewable raw materials Encapsulate Setting or Vacuum Cure Test Environmentally compatible Macromelt Molding Process Flow Insert Electronics 2 3 Overmold Test

What is Macromelt Molding? What is Macromelt Molding? Types of Macromelt Molding Materials Automotive Electronics Polyamide Polyolefin PAX Hotmelt Product Macromelt OM Macromelt Q Macromelt OM730 Service Temp +150-20 to +100-20 to +150 inherently stable > +200 Molding Temp +180 to +240 +180 to +200 +200 to +240 Macromelt 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. Viscosity range 1,000 to 7,000 5,000 to 15,000 ca. 2,000 ( mpa.s ) Shore Hardness A80 to D50 A60 to A90 D42 Adhesion Properties Superior adhesion to Superior adhesion to PP, passes reflow process plastics e.g. ABS, PBT, PVC PE, PET UL94 V-0 - - 1. Water-tight connector 2. Micro-switch Three Main Application Groups of Macromelt 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. 3. Absolute angle sensor Connector potting Hotmelts are used for sealing the plug and also for cable strain relief. 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. 4. Intelligent battery sensor 5. Air quality sensor 6. Temperature sensor 4 5

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

Molding Machine & Mold Set Molding Machine & Mold Set Molding Machine & Mold Set Mold Set Aluminum can be used as the material for making the mold set for Macromelt Molding due to Supply Molding Product Customer Supply System 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. Molding Machines There are many types of molding machines available: For small-scale production with manually opened mold set. Hotmelt Adhesives Technical Support Melting Unit Supplier Molding Machines Mold Sets 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 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 8 9

Technical Information Technical Information Product Range for Macromelt 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. Casting Resins for Electronic & Electrical Applications Henkel also offers casting resins based on epoxy and polyurethane. Their properties can be adjusted in many ways by modifying their chemical compositions. They can be engineered to be very hard and impact-resistant or soft and elastic. With low processing viscosity, they can fill even the smallest gaps. Casting Resins Polyamide General Overview Casting Applications: Product Test Method OM652 OM657 6208 6208S OM633 OM638 OM641 OM646 OM673 OM678 OM648 OM730 Properties Color - Service Temp Range Softening Point Viscosity at +210 C (mpa.s) - +100 +100 +130 +130 +140 +130 ASTM E28 +155 +155 +175 +175 +185 +175-20 to +150 > +200 after curing ASTM D3236 4,000 3,000 3,500 7,000 3,000 7,300 ca. 2,000 Shore Hardness ISO 868/15s A77 A82 A90 A92 A90 A93 D42 Creep Resistance Cold Flexibility Flammability Low temp. storage Special Properties Henkel Method MH11 +125 +130 +155 +155 +130 +155 > +200 ASTM D3111-50 -40-30 -35-40 -30-15 UL94 File E182771 Henkel Method MH40 V-0 V-0 V-0 V-0 V-0 - - Good cold flexibility RTI value for 6208S: 95 C UV stabilized -40 1000h Moisture curable Adhesion Properties Substrate PA6.6 Good Good Moderate Moderate Moderate Moderate Moderate PVC Good Good Good Excellent Good Moderate Good ABS Good Good Moderate Moderate Moderate Moderate Moderate 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. Technical Information Casting Resins General Overview 1. Antenna coil 2. Connector and micro switch 3. Transformers Product CR 8101 CR 3127 CR 3311 CR 5441 CR 6127 Hardener UK 5400 CR 4300 UK 5600 CR 4300 CR 4300 Mixing ratio (weight) 4:1 5:1 100:25 100:45 85:15 Properties Color Light brown Light brown Colorless Light brown white & black Viscosity at 20 C mixed (mpa.s) 2650 3400 3200 1000 2400 Potlife at 20 C (min) 60 90 30 25 2-15-90 Electrical Properties: Volume Resistivity DIN IEC 60093 ~ 10 12 Ω cm Dielectric Strength DIN IEC 60243-1 ~ 20 kv/mm The electrical values of OM648 and OM720 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. Shore hardness D 35-45 D 60-70 000 40 D 50-60 A 84 Flammability UL94 - V-0 - - V-0 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. 10 11

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