Macromelt Molding
What is 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.
Highlighted Features
Encapsulates fragile/delicate components
• No damage to components
Injection temperature (°C)
Low Injection Pressure
Total Cost Reduction
• Eliminates traditional housings and cases used in potting.
400
350
Injection Molding
300
• Saves energy by eliminating the heat curing process.
250
• Uses less adhesive for PCB encapsulation.
200
150
Macromelt Molding
100
Injection temp: 180-240°C
Injection pressure: 5-40 bar
50
0
0 200 400 600 800 1000 1200 1400
Injection pressure (bar)
Improved Productivity
No chemical reaction: single-component material
• Simple and clean process
2-Component
Casting Resins
Macromelt
Molding
Hours - Days
Seconds - Minutes
Process Time
• Fast cycle times (10 - 50 seconds)
Machine
Maintenance
Every day
Once a week
Superior Material Properties
Moldability
• Excellent electric insulation and water resistance
• Flexible and miniaturized product design
Chemical resistance
Low flammability
• Depending on their chemical basis, the molding products
are resistant to gasoline, oils, alcohols, acids and alkalis
• UL94 V-0 available
• Thermal cycle resistance, cold resistance, temperature
resistance (from -40°C to +150°C)
Application Case Sensor: 2C Casting vs. Macromelt Molding
Current Technology
Low Pressure
Macromelt Molding
16g/unit (Casting)
4g/unit
(PA Hotmelt)
Cost of Adhesive/kg
€X
€ 2X
• Saving in production time
Adhesive Cost/unit
€Y
€ Y/2
• Saving in production space
2 hours
< 1 min
Occupies space for case
storage & curing
No space for case
storage nor curing
Adhesive
Consumption/unit
Production Cycle/unit
Production Space
Required
Water-tight encapsulation with adhesion
Excellent thermal durability characteristics
• Mold made of aluminum helps to reduce cost.
Effective strain relief
Results after changing to Macromelt Molding:
• Adhesive cost saving = 50%
• Saving in component and energy costs
• Much better water-proof quality
Above data are taken from a real reference case
Process Flow Advantage of Macromelt Molding
Traditional Casting/Potting Process Flow
Mold Case
Insert
Electronics
Palletize
Encapsulate
Setting or
Vacuum
Preheat
Cure
Test
Based on non-toxic and renewable raw materials
• Environmentally compatible
Macromelt Molding Process Flow
Insert
Electronics
2
Overmold
Test
3
What is Macromelt Molding?
Macromelt Molding Applications
Automotive Electronics
Types of Macromelt Molding Materials
Product
Service Temp (°C)
Molding Temp (°C)
Viscosity range
( mPa.s )
Shore Hardness
Adhesion Properties
UL94
Macromelt Molding Applications
What is Macromelt Molding?
Polyamide
Macromelt® OM
Polyolefin
Macromelt® Q
PAX Hotmelt
Macromelt® OM730
-40 to +150
-20 to +100
-20 to +150
inherently stable > +200
+180 to +240
+180 to +200
+200 to +240
1,000 to 7,000
5,000 to 15,000
ca. 2,000
A80 to D50
A60 to A90
D42
Superior adhesion to
plastics e.g. ABS, PBT, PVC
Superior adhesion to PP,
PE, PET
passes reflow process
V-0
-
-
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
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
5. Air quality sensor
4. Intelligent battery sensor
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.
6. Temperature sensor
4
5
Macromelt Molding Applications
Macromelt Molding Applications
Macromelt Molding Applications
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
6
Molded connectors / Sensors with water-tightness & strain relief
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
• Lower injection pressure of the process
Supply
Molding Product
Supply
System
Customer
• 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
Molding Machines
Mold Sets
Melting Unit Supplier
• 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
System Solution
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.
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
• Check requirements
• Spot test, if required
• Develop new
product
8
Prototyping
• Trial with mold set
• Produce molded
samples for eval­uation
Evaluation by
customer
• E
nvironmental
resistance
• Chemical resistance
• etc.
Prepare
for production
• Check requirements
• Decide right specification
Project
completion
• S
upply hotmelt and
machines
• Start production
9
Technical Information
Casting Resins
Product Range for Macromelt Molding
for Electronic & Electrical Applications
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.
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 Applications:
Polyamide General Overview
Test
Method
OM652
OM657
6208
6208S
OM633
OM638
OM641
OM646
OM673
OM678
OM648
OM730
-
Amber
Black
Amber
Black
Amber
Black
Amber
Black
Amber
Black
Black
Amber
-
-40 to
+100
-40 to
+100
-40 to
+130
-40 to
+130
-40 to
+140
-40 to
+130
-20 to
+150
ASTM E28
+155
+155
+175
+175
+185
+175
ASTM D3236
4,000
3,000
3,500
7,000
3,000
7,300
ca. 2,000
ISO 868/15s
A77
A82
A90
A92
A90
A93
D42
Henkel
Method MH11
+125
+130
+155
+155
+130
+155
> +200
ASTM D3111
-50
-40
-30
-35
-40
-30
-15
Technical Information
UL94 File
E182771
V-0
V-0
V-0
V-0
V-0
-
-
Casting Resins General Overview
Product
Casting Resins
Technical Information
Properties
Color
Service Temp
Range (°C)
Softening Point
(°C)
Viscosity at
+210°C (mPa.s)
Shore Hardness
Creep Resistance
(°C)
Cold Flexibility
(°C)
Flammability
Low temp. storage
Henkel
Method MH40
(°C)
Special Properties
> +200
after curing
-40
1000h
RTI value
Good cold
for 6208S:
flexibility
95°C
UV
stabilized
Moisture
curable
Adhesion Properties
Substrate
3. Transformers
Product
CR 8101
CR 3127
CR 3311
CR 5441
CR 6127
Hardener
UK 5400
CR 4300
UK 5600
CR 4300
CR 4300
4:1
5:1
100:25
100:45
85:15
Light brown
Light brown
Colorless
Light brown
white & black
2650
3400
3200
1000
2400
60
90
30
25
2-15-90
D 35 - 45
D 60 - 70
000 40
D 50 - 60
A 84
-
V-0
-
-
V-0
Mixing ratio (weight)
Properties
PA6.6
Good
Good
Moderate
Moderate
Moderate
Moderate
Moderate
Color
PVC
ABS
Good
Good
Good
Good
Good
Moderate
Excellent
Moderate
Good
Moderate
Moderate
Moderate
Good
Moderate
Viscosity
at 20°C mixed (mPa.s)
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.
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
2. Connector and micro switch
1. Antenna coil
Potlife at 20°C (min)
Shore hardness
Flammability UL94
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.
11
12.10 5000921
Nordic: IDH 1517280
Henkel Your partner worldwide
Headquarter
Henkel AG & Co. KGaA
Henkelstr. 67
40589 Duesseldorf
Germany
Tel.: +49 211 797 9583
www.henkel.com
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
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
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
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
Finland
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Äyritie 12 A
01510 Vantaa
Puh.: 0201 22 311
Fax: 0201 22 3541
www.henkel.fi
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
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