Mold Case
Encapsulate
Insert
Electronics Overmold Test
Cure Setting or
Vacuum Test
Palletize ElectronicsInsert Preheat
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.
Process Flow Advantage of Macromelt Molding
Traditional Casting/Potting Process Flow
Macromelt Molding Process Flow 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
• Thermal cycle resistance, cold resistance, temperature resistance (from -40°C to +150°C)
Based on non-toxic and renewable raw materials • Environmentally compatible
Application Case -
Sensor: 2C Casting vs. Macromelt Molding
Current Technology Macromelt MoldingLow Pressure Adhesive
Consumption/unit 16g/unit (Casting) (PA Hotmelt)4g/unit
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
No space for case storage nor curing
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
Highlighted Features
Moldability
• Flexible and miniaturized product design Low flammability
• UL94 V-0 available Effective strain relief
400 350 300 250 200 150 100 50 0 0 200 400 600 800 1000 1200 1400 2-Component
Casting Resins Macromelt Molding Process Time Hours - Days Seconds - Minutes
Machine
Maintenance 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.
Above data are taken from a real reference case
What is Macromelt Molding?
What is Macromelt Molding?
Injection Molding
Macromelt Molding Injection temp: 180-240°C Injection pressure: 5-40 bar
Injection pressure (bar)
Injection temperatur
5
Polyamide Polyolefin PAX Hotmelt
Product Macromelt® OM Macromelt® Q Macromelt® OM730
Service Temp (°C) -40 to +150 -20 to +100 -20 to +150 inherently stable > +200 Molding Temp (°C) +180 to +240 +180 to +200 +200 to +240 Viscosity range ( mPa.s ) 1,000 to 7,000 5,000 to 15,000 ca. 2,000
Shore Hardness A80 to D50 A60 to A90 D42
Adhesion Properties Superior adhesion to plastics e.g. ABS, PBT, PVC
Superior adhesion to PP, PE, PET
passes reflow process
UL94 V-0 -
-Macromelt Molding Applications
Automotive Electronics
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.
1. Water-tight connector
2. Micro-switch
3. Absolute angle sensor
4. Intelligent battery sensor 5. Air quality 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.
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.
Types of Macromelt Molding Materials
Three Main Application Groups of Macromelt Molding Products
Macromelt Molding
Applications
What is Macromelt Molding?
What is Macromelt Molding?
8. Antenna coil
9. GND terminal
Mobile phone battery
Grommets / Sockets
Molded connectors / Sensors with water-tightness & strain relief
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.
Automotive Electronics
Macromelt Molding
Applications
Macromelt Molding
Applications
7. Other kinds of sensors
Macromelt Molding Applications
9
Molding Machine & Mold Set
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.
Mold Set
Aluminum can be used as the material for making the mold set for Macromelt 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.
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.
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.
Molding Machine & Mold Set
Molding Machine & Mold Set
Hotmelt Adhesives Technical Support Supply Molding Product Supply System Supply Melting Unit Molding Machines Mold Sets Melting Unit Supplier
Customer
Select right hotmelt
• 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 specifi-
cation
• Supply hotmelt and machines • Start production
Casting Resins
1. Antenna coil 2. Connector and micro switch
3. Transformers
Casting 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.
Technical Information
Casting Resins General Overview
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 Shore hardness D 35 - 45 D 60 - 70 000 40 D 50 - 60 A 84 Flammability UL94 - V-0 - - V-0
for Electronic & Electrical Applications
Technical Information
Product Range for Macromelt Molding
Polyamide General Overview
Product MethodTest OM652OM657 6208S6208 OM633OM638 OM641OM646 OM673OM678 OM648 OM730
Properties
Color - AmberBlack AmberBlack AmberBlack AmberBlack AmberBlack Black Amber Service Temp Range (°C) --40 to +100 -40 to +100 -40 to +130 -40 to +130 -40 to +140 -40 to +130 -20 to +150 Softening Point
(°C) ASTM E28 +155 +155 +175 +175 +185 +175 after curing> +200
Viscosity at
+210°C (mPa.s) 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
(°C) Method MH11Henkel +125 +130 +155 +155 +130 +155 > +200
Cold Flexibility
(°C) ASTM D3111 -50 -40 -30 -35 -40 -30 -15
Flammability UL94 File E182771 V-0 V-0 V-0 V-0 V-0 - -Low temp. storage
(°C) Method MH40Henkel
-40 1000h
Special Properties Good cold flexibility for 6208S: RTI value 95°C
UV
stabilized 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
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
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.
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 60093 ~ 1012 Ω cm
Dielectric Strength DIN IEC 60243-1 ~ 20 kV/mm The electrical values of OM648 and OM720 are not available.
Technical Information
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
Headquarter
Henkel AG & Co. KGaA Henkelstr. 67 40589 Duesseldorf Germany Tel.: +49 211 797 9583 www.henkel.com www.macromelt-molding.com Benelux Henkel Nederland b.v. Adhesive Technologies Postbus 2100 - 3430 CM Nieuwegein Brugwal 11 - 3432 NZ Nieuwegein The Netherlands Tel.: +31 30 607 38 50 Fax: +31 30 607 38 51 www.henkel.nl www.macromelt-molding.com Henkel Belgium N.V. Adhesive Technologies Havenlaan 16 1080 Brussel Belgium Tel.: +32 2 421 25 55 Fax: +32 2 421 25 99 www.henkel.be www.macromelt-molding.com Italy
Henkel Italia S.p.A. Via Amoretti, 78 20157 Milano Italia Tel.: 02-357921 Fax: 02-3552550 www.henkel.it www.macromelt-molding.com Turkey
Türk Henkel Kimya San. ve Tic. A.Ş. Kayışdağı cad. Karaman Çiftliği Yolu Kar Plaza D blok 34752
İçerenköy - İstanbul - Türkiye Tel.: 0216 579 4000 Fax: 0216 579 4041 www.henkel.com.tr www.macromelt-molding.com Nordic Denmark Henkel Norden AB Helgeshøj Allé 20-22 2630 Tåstrup Tel.: 43 301 301 Fax: 43 301 310 www.henkel.dk www.macromelt-molding.com Finland Henkel Norden Oy Äyritie 12 A 01510 Vantaa Puh.: 0201 22 311 Fax: 0201 22 3541 www.henkel.fi www.macromelt-molding.com Norway Henkel Norden AB Postboks 6405 Etterstad 0604 Oslo Tel.: 23 37 15 20 Faks: 23 37 15 21 www.henkel.no www.macromelt-molding.com Sweden Henkel Norden AB Box 120 80 102 22 Stockholm Fax: 010 - 480 77 70 www.henkel.se www.macromelt-molding.com Nordic: IDH 1517280 12.10 5000921