Trusted Partnership

Henkel is Fourstar’s primary

overmolding materials partner.

With Henkel’s permission, we’re

o�ering this downloadable PDF

that includes some informative

details on low-pressure molding

and Technomelt applications.

Explore:

• What low-pressure molding is• Total cost reduction • Types of low-pressure molding materials• Common molding applications and product groups

LowPressure MoldingOverview

HenkelElectronics

2

Agenda

Technology1

Process2

Solutions3

3

AgendaTECHNOMELT– LowPressureMolding

• OverviewofTechnology• Definition• ValueProposition• Applications

• Processing• Equipment• Moldsets• Parameters

• Productsoverview• General• SpecialtyProducts

4

TECHNOMELTSolutionBriefDescription

Low Pressure Molding

Benefits

• Hotmeltpolyamidematerialdesignedforelectroniccomponents

• Itslowpressureandhighspeedsaresuitableforsensitiveelectroniccomponentsinmanufacturingenvironments

• ThetechnologyallowsforuniquedesignbeyondtheForm-Fit-Functionoftraditionalmaterials.

• Completewatertightencapsulation• Temperatureandsolventresistantmaterials• UL94-V0rated• Shortcycletime• “Green”technology– NoVOCandminimalwaste• SignificantlyLowersTCOO

5

WhatisTECHNOMELTMolding?

• TECHNOMELTMolding=LowPressureInjectionMoldingofAdhesives

• Anenvironmentally-friendlyprocesspositionedbetweenpottingandinjectionmoldingtechnologies

• Aprocesstooverorpartiallymoldcomponentspre-insertedinamoldset,likePCBs,sensors,switches,batteries,connectors,etc.

• Toprotectthemfromenvironmentalissueslikemoisture,temperature,chemicals,etc.

InjectionMolding

Potting

TECHNOMELTMolding

Pressure

Cycletime

6

ASustainableSolution

ü Highperformancepolyamidehotmelts

ü Solventfree,nosafetylabels

ü 80%ofrawmaterialsarebasedonrenewables(vegetableoils)

ü Noharmfulfumesfromthemoldingprocess

ü Longshelflife(2+years)

ü RoHSandREACHcomplaint

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LowPressureMoldingTechnologyValueProposition

ElectricalInsulation

Contact

StrainRelief

Vibration

Corrosion

Waterproof

EnvironmentalInfluences

8

LPMtypicalApplications

Encapsulating,sealing&protectingelectronic

assembly

Switches,automotiveelectronicandmedical

sensors

Sealingconnectorsandprovidingstrainrelief LEDLighting

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Agenda

Technology1

Process2

Solutions3

10

ApplicationDevelopmentTECHNOMELTSolution

PartnershipswithEquipmentVendorstoSupportDevelopment

ApplicationEngineering

• ProductDesignInput

• MaterialExperience

• ProcessOptimization

MoldDesign

• LessWeight

• SmallerFootprint

• DesignFlexibility

• Prototyping

• Form,Fit&Function

Equipment

• LowCapital

• FastCycletime

• MinimalFootprint

• Versatility

• Sustainable

TECHNOMELT

• Waterproof

• ChemicalResistant

• Impact&Vibration

• StrainRelief

• Versatile

• Reliable

1 2 3 4

11

LowPressureMoldingProcess

InsertElectronics Readytohandle&testOver-mold30– 45sec

12

Equipment Partners

Customer

Hotmelt Adhesives Technical Support

Molding Machines Mold Sets

Melting Unit Supplier

SupplyMoldingProduct

SupplySystem

SupplyMeltingUnit

13

ExamplesofAutomatedMoldingMachines

ProcessFlowofApplicationsareDeveloped

14

MoldTools

Material

• Usuallyaluminum

• Easytomill, drillandetch

• Goodreleaseofthemoldedpieces

Steelinsertsrecommendedincontactareaswithhardermetalparts

Lifetime

• Verylong,asTECHNOMELTisnotabrasivenorcorrosive

Lowermold-half

Uppermold-halfCavityRunner&Gate

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ProcessConditionsPressure&Temperature

Engineering PA: PA6, PA66, PA11

0

100

200

300

400

0 200 400 600 800 1000 1200 1400Inje

ctio

n te

mpe

ratu

re (D

eg C

)

Low Pressure Molding Injection Pressure (bar)

Traditional Plastic Injection Molding

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ProcessConditionsTemperature&InjectionTime

DegreesF

0

100

200

300

400

10 20 30 40 50 60 70 80 90 100 110 120

Seconds

TemperatureProfileduringInjection,Typical

Injectiontemperature:425°F,mold-settemperature:70°FCylindricalovermoldofPCB:0.5”diaby2.5”long

176°C

135°C112.8°C

48.9°C

27.0°C

79.5°C

WorkpieceFilled(sizedependencyex.USBstick)TemperatureonPCB Temperature1mmfromsurface

OvermoldingwithTECHNOMELTshowsnoadverseaffectsinsolderjointreliability

Un-encapsulated

EncapsulatedinTECHNOMELT

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ProcessOverview&Comparisons

MoldPlasticHousing PartstoAssembly InsertElectronics PartsPreheating

OvenCureVacuumorSettlePottingDispense PartsforTest

InsertParts OverMold(LPM) PartsreadyforTest

TraditionalPottingProcessFlow

LowPressureMoldingProcess

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CostSavingsCalculatorApplicationCaseHistory

PottedWaterSensor:• Cylindericalpartwithmountingtabsandexitingcables• Dimensions~35mm,height~15mm

TotalSavings>25%materialcostsavingsPerYEAR

Potting• PCBinhousing• Dispense• Cure• Lidattach• Securelid

LPM• Insertintomoldsetand

mold

ProcessSteps MaterialConsumption Throughput CostSavings

Potting• Density=1.06g/cc• 58ccemptyspace• 65grams pottingmaterial

required

LPM• 11grams/shot

Potting• Oneshift capacity

(5daysx8hours)=300,000pts/yr

LPM• Oneshiftcapacity=

405,000 pts/yr

Potting• Costofpottedpart=

$0.97/pt

LPM• Costofmoldedpart=

$0.78/pt

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Low Pressure MoldingBenefits

CostSavings

• Molds

• Skylining

• Nocure

TimeSavings

• Fastcycletimes

• Simpleandcleanprocess

• Minimalmaintenance

ProductionSpaceSavings

• Decreasedequipmentfootprint

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Colors

Henkel’sstandardcolorsareamberorblack

Via colored master batches you can achieve almost every color you need

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Printing

It’spossibletoprintamarkingdirectlyontothemoldedassembly

• Padprinting

• Laserprinting

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Agenda

Technology1

Solutions3

Process2

23

MaterialPropertiesTECHNOMELTMolding

• Temperatureresistance,shorttermexposure<=185°C

• Flexibility,Elongationatrupture<=800%

• Coldflexibility>=-50°C

• Goodchemicalresistancerelatedtoautomotivefluids,shorttermexposure.

• Goodchemicalresistanceregardingnon-polarliquidslikeoil,longtermexposure.

• Waterabsorption0.2to2.0%,24hat22°C

• FlameretardantpropertiesUL-listing,mainlyUL94V-0andRTIcertified

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• Performancetemperaturesfrom-40°Cto170°C

• Excellentadhesivepropertiestovarietyofsubstrates

• Amber,Black,WhiteandTransparentmaterialsolutions

TechnologyOverviewMoldingResins

• Thermoplasticmaterials,UL94V-0• Naturallyoccurringrawmaterials• Notoxicfumesduetocure• Applicationviscosityfrom

1,000– 10,000cps• ApplicationPressurefrom20to500psi

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Subgroupintomarketareas.• LED/light(PA668,PA648,AS4226)• IndustrialComponents– UVexposure(PA

6208BLACK,PA648,PA649,PA6344)• Automotive/Sensors(PA341,PA658,PA

2384,PA2692

TECHNOMELT Product ReviewProduct PA 633/638 PA 641/646 PA 652/657 PA 673/678 PA 6208/6208 BLACK

Key Property Generalist product High Strength & hardness

High Adhesion & cold flexibility High working Temp Outdoor performance

(f2)

Working Temp. -40 to 130 oC -40 to 130 oC -40 to 100 oC -40 to 140 oC -40 to 100 oC

Hardness A 90 A 92 A 77 A 88 78 A

Strength 5.2 N/mm2 11 N/mm2 2.7 N/mm2 5.7 N/mm2 3.4 N/mm2

Specialtyproducts:• PA648:ImprovedUVresistance• PA341:BlazeorangecolorforElectricvehicles• PA658:Hydrolysisresistantforimproved85/85performance• PA2384:Increasedhardnessandimprovedalcoholresistance• PA668:UVStabilizedWhiteforLEDapplications.• PA2692:HighTemperature,150°C

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HenkelInnovationsWhitePolyamide– TECHNOMELTPA668

TECHNOMELTPA668whiteProperties

• UVstabilised

• Goodmechanicalproperties

• SuitableforLEDapplications

• -40upto105°C

• UVresistance,doesnotyellowovertime

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HenkelInnovationsSolvent/Chemicalresistant– TECHNOMELTPA2384

PA2384isasolventandchemicallyresistantmaterial• Polarsolventandhydrocarbonresistant• Highhardness• Highoperatingtemperature

PA6208vsPA2384mechanicalsbeforeandafterIPAexposure

7DaySubmersionTest 8WeekSubmersionTest

IPAtreated

Nottreated Nottreated

Treated

13.61g

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ThermallyConductiveUnderDevelopment– Q3/2015

• ProjectGoal:DevelophigherThermalConductiveTECHNOMELT

• StandardTECHNOMELTresinisinsulatingwith~0.2W/mK

• TCTMtoallowheattransferthroughmoldedencapsulate

• Targetingformulaswith>0.5W/mK,>0.7W/mK,and>1W/mKperformance

Allowsforheatdissipationthroughthe

moldedencapsulantlayer

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TECHNOMELTProductsLowPressureMoldingforCBP

LowPressureMolding

IncreasedHardness

AdhesiontoPlastics

SolventResistant

UVResistant

HighTemperatureResistance

AmberBlazeOrange BlackAmber Black Amber BlackWhiteAmber Black

TECHNOMELTPA646

TECHNOMELTPA341

TECHNOMELTPA641

TECHNOMELTPA638

TECHNOMELTPA633

TECHNOMELTPA2384

TECHNOMELTPA6344

TECHNOMELTPA668

TECHNOMELTPA673

TECHNOMELTPA678

TECHNOMELTPA652

TECHNOMELTPA687

TECHNOMELTPA682

TECHNOMELTPA657

TECHNOMELTPA6208

TECHNOMELTPA6208BLACK

TECHNOMELTPA2692

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