One. What is the Macromelt® Low Pressure Injection Molding Process?
Macromelt low-pressure injection molding process is a packaging process method that injects the encapsulation material into the mold and quickly cures (5~50 seconds) at a very low injection pressure (1.5~40bar) to achieve insulation, temperature resistance, impact resistance, vibration reduction, moisture, waterproof, dustproof, chemical corrosion resistance and other effects. Henkel Technologies provides the high-performance Macromelt series of specialty hot melt adhesives as encapsulation materials for the packaging and protection of delicate and sensitive electronic components, including: printed wiring boards (PCBs), automotive electronics, mobile phone batteries, wiring harnesses, waterproof connectors, sensors, microswitches, inductors, antennas, loop cables, etc.
Two. Benefits of the Macromelt® low-pressure injection molding process
1. Improve the performance of end products:
1) The injection pressure is extremely low, the components are not damaged, and the defective rate is extremely low
Three. For the defect of excessive pressure in the traditional injection molding process, the Macromelt series special compounds only need a small pressure after melting to make them flow into a small mold space, so that they will not damage the fragile components that need to be packaged, and the scrap rate is greatly reduced
Low pressure injection molding process Traditional engineering plastic injection molding
Material Henkel Macromelt hot melt adhesive ABS, PBT, PP, etc
Injection pressure 1.5~40bar 350~1,300bar
Injection temperature 190~230°C 230~300°C
Mold clamping pressure 1 ton more than 50 tons
Mold material: aluminum steel
Damage to the mold No wear wear
2) Excellent protection effect
Good sealing: Macromelt series special compounds have good bonding properties after melting, which can effectively seal, moisture-proof, waterproof, dustproof and chemically resistant to the encapsulated components.
High and low temperature resistance: The ambient temperature range is -40 °C to 150 °C, which can be applied to a variety of harsh production environments and use environments.
Impact resistance: after molding, it can reach hardness Shore A 60~90 or Shore D 40, with good toughness, which can slow down the impact from the outside world.
Electrical insulation: volume resistance between 1011~1014, can be used as insulation material.
Flame retardancy: Macromelt series hot melt adhesives also have excellent flame retardant properties and comply with UL94V0 standards.
3) Eco-friendly products
Henkel's Macromelt series of hot melt adhesives comply with the EU RoHS directive, do not contain any solvents, and are non-toxic and harmless one-component environmentally friendly materials.
2. Shorten the product development cycle and greatly improve production efficiency
The forming mold can be made of cast aluminum mold instead of steel, so it is very easy to design, develop and process the mold, and shorten the development cycle.
In addition, compared with the time-consuming two-component potting process, the process cycle of low-pressure hot melt adhesive injection molding can be shortened to a few seconds to tens of seconds, which greatly promotes production efficiency.
Comparison of low-pressure hot melt adhesive injection molding process and potting process
Low pressure hot melt adhesive injection molding potting
Temperature resistance -40~150°C ∽180°C
The component size is generally within the size of the business card and is unlimited
Process cycle No chemical reaction 20~50 seconds Chemical reaction takes about 24 hours
3. Save total production costs
First of all, the equipment cost of the low-pressure injection molding process is low. Traditional injection molding equipment systems are generally costly, including the purchase of high-pressure injection molding machines, water cooling systems and expensive steel molds. The low-pressure injection molding process equipment system is generally relatively simple, consisting only of three parts: hot melt adhesive machine, working console and mold.
Secondly, due to the extremely low injection pressure, the mold can use cast aluminum mold, which is easy to design, develop and process the mold, which can save material cost and development cycle.
If the low-pressure injection molding process is used instead of the traditional potting process, the shell for potting and the cost of post-heating curing can also be saved.
Finally, due to the low pressure and low temperature, the scrap rate of the finished product can be greatly reduced, avoiding unnecessary waste.
Therefore, the choice of low-pressure injection molding process can not only greatly improve production efficiency, reduce the defective rate of finished products, but also help manufacturers establish cost advantages overall
