Low Pressure Molding
LOW PRESSURE INSERT MOLDING
Henkel, the global leader in adhesives, and The Cavist Corporation, application engineering and equipment experts in the field of low pressure insert molding, have partnered to offer a complete solution for the gentle over-molding and encapsulation of delicate electronic components.
Low pressure molding is an innovative manufacturing process between injection molding and potting. It is injection molding at very low pressures with hot melt adhesives. It is a cost effective alternative to epoxy potting for protection of fragile electronic components. When used for cable and connector molding, it offers superior strain relief compared to conventional plastic injection molding.
Process Flow Advantage of Low Pressure Molding
TRADITIONAL POTTING PROCESS FLOW
LOW PRESSURE PROCESS FLOW
The Low Pressure Molding process provides many benefits.
• Complete sealing of the components, providing water-tight encapsulation • Effective strain relief
• Low viscosity materials allow for low injection pressures of 20 to 500 psi • Allows gentle pre-molding of connectors • Components and wires are not
damaged or dislocated in cavities • Easy to encapsulate fragile components • No hazardous fumes from
materials or processing
• Short (15-45 seconds) cycle time to complete part
Headline
Helvetica Neue 75 Bold
20pt/25pt - tracking 3
“Overmolding replaces both the housing
and potting in just one operation.”
Seal large PC boards with
external connectors
Encapsulation of sensitive
electronics prior to
conventional overmolding
Overmold various
electronic shapes
Packaging of sensitive
“Adhesive Materials offer
superior strain relief.”
Seal multi-wire connectors
Mold strain relief and grommets
Mold connectors with strain relief
Superior strain relief for
modular connectors without
mechanical crimping
MACROMELT
®DATA -
Based on General Values
Properties Test Method Unit OM 633 / OM 638 OM 641 / OM 646 OM 652 / OM 657 OM 673 / OM 678 MM 6208 / MM 6208S PHYSICAL
Color amber / black amber / black amber / black amber / black amber / black
Specific gravity DIN 53479, S S.G. 0.98 0.98 0.98 0.98 0.98
Working temperature Henkel Method °C -40 to +130 -40 to +130 -40 to +100 -40 to +140 -40 to +150
Hardness ASTM D 2240-85 Shore A 90 92 77 88 78
Elongation @ rupture ASTM D 638-00 % 400 800 400 500 600
Softening point, ASTM E 28-99 °C 175 175 155 187 / 185 150 – 160
Ball & Ring
Molding temperature Henkel Method °C 200 to 240 210 to 240 180 to 280 210 to 240 190 to 230
Viscosity @ 210°C ASTM D 3236-88 mPas 3700 7000 4100 3400 3600
ELECTRICAL
Dielectric ASTM D150-95 4.5 / 4.7 5.1 / 5.5 6.2 / 6.3 4.9 / 4.9 6.1 / 6.3 constant @ 1 kHz
Volume resistivity D257-93 Ohm cm 1.7E15 / 2.4E13 6.3E12 / 1.7E12 1.0E12 / 7.2E11 1.90E12 / 1.90E12 1.9E11 / 1.6E11 Dielectric strength ASTM D149-97a kV / mm 24 / 19 25 / 22 14 / 15 20 / 20 23 / 23
RATINGS & TEST RESULTS
FDA category FDA Adhesives 175.105 (OM 633) 175.105 (OM 641) 175.105 (OM 652) 175.105 (OM 673) 175.105 (MM 6208)
Flammability rating U/L 94 V-O V-O V-O V-O V-O
HENKEL MACROMELT
®LOW PRESSURE MOLDING MATERIALS
Henkel is the world leader in high performance adhesive materials. The Macromelt® OM line of low pressure molding materials are
innovative, specially-modified thermoplastic polyamide hot melts made especially for low pressure molding.
Macromelt®products melt and flow at low viscosities (1,000 to 10,000 cps), allowing for the low injection pressure process. Macromelt®
offers very good adhesion to various substrates, including PVC, PA6.6, PUR, and PP. Since they are based on adhesive technology, they bond to form a watertight and chemical seal. These hot melts cure quickly by cooling so there are no toxic fumes and cycle times are short. The entire line of Macromelt®OM products is UL94-V0 rated. The materials are available in amber, black and custom colors.
The Cavist Corporation specializes in low pressure molding. The low pressure molding system requires careful engineering of the mold-set to achieve consistent, high volume production. This process allows you to utilize cost effective aluminum mold-sets. Either single or multi-cavity mold-sets can be used. Cavist is the low pressure molding supplier of:
• Quality application engineering
• Mold-set fabrication or guidance to create your own mold-sets • Prototyping
The Moldman™ Low Pressure Injection Molding Technology is the best
equipment for dispensing Macromelt® Molding materials to create a
quality component.
• High capacity • User friendly and safe • Small footprint • Injection profiles • Simple to operate • Made in U.S.A. • Easy set-up with
touch screen Henkel Corporation 15350 Barranca Parkway Irvine, CA 92618 949-789-2500 • Fax 949-789-2595 www.electronics.henkel.com The Cavist Corporation 3545 Airway Drive #112 Reno, NV 89511 U.S.A.
775-332-1600 • Fax 775-332-1601 www.cavist.com • [email protected]
• Molding equipment incorporating the latest Nordson Corporation melt units • Contract molding services
Henkel Corporation Irvine, California U.S.A.
www.electronics.henkel.com ® and ™ designate trademarks of Henkel Corporation or its Affiliates. ® = registered in the U.S. and elsewhere. © Henkel Corporation, 2005. All rights reserved. 2894/LT-4182 (4/2005)
