at precision ato-m overmoulding

Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission


Hethel Engineering Centre

Chapman Way, Hethel

Norwich, Norfolk UK

NR14 8FB

t: +44 (0) 1953 859133

e: [email protected]

atprecision.co.uk

A DIVISION OF

mailto:[email protected]



Active Technologies Over-Moulding (ATO-M)

Equipment, Materials Challenges, Solutions & Case Studies

Active Precision Over mould Market Target Exposure

Connectors PCBA Potting

Engine Components Heat shrink LED Lighting Cable Processing

ATO-M

O-M Fault Analysis Support

O-M Product Design

O-M Product Manufacture

O-M Material

Sales

After Sales / Service &

Repair

Tooling & Equipment

Sales

ATO-M Customer Supporting Objectives

ATO-M


O-M Product Design


O-M Material

Sales


Repair

Tooling & Equipment

Sales

Key Objectives – Tooling and Equipment Sales

• Tooling & Equipment Sales • Offered a range of ATO-M

Precision over-mould machines • Technical Support for customer

obsolescence replacement product(s)

• Product custom tooling solutions, including RP Over-moulded solutions

• Prototype Tooling through to Production Volume solutions

• New Materials for tooling • New technology developments

for equipment • Training Programs / Open Days

Key Objectives – O-M Fault Analysis Support

ATO-M


O-M Product Design


O-M Material

Sales


Repair

Tooling & Equipment

Sales

• O-M Fault Analysis Support

• Customer support of field failure analysis of component parts and or materials.

• Partnered with Henkel • Tooling analysis • Mould Flow (Design

Analysis) • FEA (Design Analysis) • Environmental Testing of

customer designs

Key Objectives – O-M Product Design

• O-M Product Design • Engineering Design support for

application integration • Custom design services • FEA Analysis • Mould-Flow Analysis • 3D Cad Modelling • 2D Drawing • Liase with customer suppliers

for design optimisation and manufacture

• APQP / PPAP – FAIR / ISIR reporting first off part prototypes or production tooling

• Marketing Literature (Instructions / Manual)

ATO-M


O-M Product Design


O-M Material

Sales


Repair

Tooling & Equipment

Sales

Key Objectives – O-M Product Manufacture

ATO-M


O-M Product Design


O-M Material

Sales


Repair

Tooling & Equipment

Sales

• O-M Product Manufacture • Custom Manufacturing Facilities

at Hethel using ISO9001 Standards

• Manufacturing Engineering support for application integration to customer production environment

• Takt Time Analysis Reporting – Labour Cost Analysis (6 Sigma)

• Cell Layout Proposals • PPAP – FAIR / ISIR reporting first

off production process • Control Plan Documentation • Process Documentation • Quality Inspection Process to

ISO9001 Standards

Key Objectives – O-M Material Sales

ATO-M


O-M Product Design


O-M Material

Sales


Repair

Tooling & Equipment

Sales

• O-M Materials Sales • Henkel material sales

• Macromelt ® • Macroplast ®

• Introduction of NEW PA technologies from Henkel

Key Objectives – After Sales / Service & Repair

ATO-M


O-M Product Design


O-M Material

Sales


Repair

Tooling & Equipment

Sales

• After Sales / Service & Repair • Optional service contracts /

maintenance agreements, replacement tooling or inserts.

• Follow up with customers • Breakdown emergency contract

agreements



Over mould Equipment



Low Pressure Overmoulding Equipment

Active Precision, a Division of Active Technologies and experts in product design,

manufacturing, material selection, machine design & production with Nordson,

a global supplier of adhesive application systems has partnered to offer a complete

solutions for low pressure over moulding system design.



• Field-proven, all-electric technology delivers outstanding durability and value.

• These melt units are ideal for all-electric dispensing via a mould tool or manual/handgun operations.

• Choose from tank capacities of 4, 10, 16, 25, 50 and 100 litres.

• Economize using fixed-speed AC drive and gear pumps with low and high output rates.

• Simplify daily operation using intuitive graphic operator interface, system status at-a-glance and continuously updated temperature monitoring.

• Reduce wear and tear on equipment with low-pressure operation.

• Select 2-, 4-, or 6-gun operation and expand as your production needs change.

• Enhance performance of hot melt adhesives. Leading Zone Concept prevents any control zone temperature from exceeding the leading zone temperature, causing all zones to reach set point temperature simultaneously.

• Reduce adhesive spilling and waste with large, accessible tank opening.

• Access all components quickly and easily using large, removable side panels.

• Connect to a personal computer via RS 232 port for melt diagnostics, setup and programming.

Processing Solutions - Low Pressure Injection Moulding (LPIM)



14

Description Low Pressure Over-moulding equipment Manual Load, Automatic mould rotary based low pressure mould system Other design variants available on request Control System PLC

Cycle Time Product/Shot size specific, 10-40s typical

Volume >1M components / year

Locations used Mexico, China and Slovenia

Processing Solutions - LPIM Indexing Table Example

Typical product


Material Challenges?



Low Pressure Overmoulding Materials

Active Precision, a Division of Active Technologies and experts in product design,

manufacturing, material selection, machine design & production with Henkel, the global

leader in adhesive technologies has partnered to offer a complete solution for low

pressure over moulding / encapsulation.



• The challenge is encapsulating and over-moulding electronics without causing failure or destruction

• Hard, crystalline polymers do not adhere easily to other substrates

• Crystalline polymers require high shear (high pressure) destroying electronic components and damages cables

• Some soft elastomers can over-mould delicate components however heat dissipation issues can cause in-service failures later

• Consider adhesion/cohesion model

Polymer Facts & Trends - The Challenge



• Hot Melt Polyamide Adhesive (HMPA‘S) resins protect electronic components • Design can be formed (moulded) in to 3D prescribed shape to optimize space available

within an assembly

• Provides aesthetically pleasing solution

• Ability to over mould cabled products, whilst also creating strain relief protection

• Recyclable compared to epoxy and PU.

• Good adhesion/bonding to other polymers

• Creating sealing of components (water tight encapsulation) IP67 Levels

• Low pressure moulding material can be used as a solution to encapsulate printed circuit board assemblies (PCBA’s), provides additional protection to electronic components

Polymer Facts & Trends - Protecting Electronics



Comparison of Hot Melt Polyamide Adhesive (HMPA‘S) to common materials used to protect electronic components

Parameter 3D

Shape detail

Pack Space

Cable Exit /

Strain Relief

Shock RDSW /Elec.

IP rated protect

PCB/elec.

Cure time

WIP Adhesion

& cohesion

End of Life

Recycle

HMPA YES LOW YES HIGH HIGH 5 SEC LOW MEDIUM YES

2 X PART PU POTTING NO MEDIUM NO HIGH HIGH HRS HIGH HIGH NO

2 X PART EPOXY POTTING NO MEDIUM NO MEDIUM HIGH HRS HIGH HIGH NO

INJECTION MOULDED POLYMER (CLIPPED/WELDED)

YES MEDIUM YES MEDIUM LOW 3 SEC LOW MEDIUM NO

CONFORMAL COATING NO LOW NO LOW HIGH MINS MED HIGH NO

Polymer Facts & Trends -Comparison Matrix



Protecting Electronic Components with new thermoplastics & Elastomers

Changes Purpose Consequences

Thermosets to Thermoplastics replacing 2 x part potting compounds

with thermoplastic hot melts

Use of HMPA increases, unit volume declines due to cost and need for less

material

Amorphous to Crystalline polymers harder, stiffer polymers replacing metals should make incorporating sensors and

electronics more practical

Moderate to High temperature materials complex polymers replacing metals and

rubbers 2 x shot moulding provides protection

and manufacturability

Approx. 25% increase in volume of Plastics

driver for polymer research & development

could enable UK to take lead in complex automated manufacturing

Protecting Electronics



• Thermal recovery and destruction of HMPA’s in domestic incineration plants, free from any toxins or hazardous compounds

• Reduced part volume of HMPA’s reduce recovery process

• Most new high performance polymers and elastomers can be recovered mechanically, re-ground and recycled

• Many new elastomers can be recycled infinitely

End of Life Cycle Recovery & Recycling Management



Solutions



Injection Moulding

Casting

Macromelt ® Moulding p

ress

ure

cycle time

What is Macromelt Moulding?

Macromelt® Moulding = Low Pressure, Adhesive, Injection Moulding A process innovation positioned between casting and injection moulding technologies



• High performance polyamide hotmelts

• Solvent free, no safety labels

• 60-80% of raw materials are based on renewables (vegetable oils)

• Long shelf life (2+ years)

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

Macromelt Technology Background



• Low Pressure

– Injection pressure between 2 and 40 bar

– No damage of electronic parts

– Moulds can be made of aluminum (low costs)

• Adhesive

– To manufacture parts (connector, PCBs, etc.) which are water tight

– To obtain strain relief on cables

– Products based on natural raw materials – environmentally compatible

• Injection Moulding

– Cycle times typically between 10 and 50 seconds

– Allows higher out than with casting applications

– Clean and simple to use process

Technical Features



Benefits

• Cost Savings

– Moulds can be made of aluminum instead of steel

– Less adhesive needed compared to traditional casting

– Saves energy by eliminating the heat curing process

• Time Savings

– Fast cycle times (10 to 50 seconds); no extra time for curing

– Simple and clean process with low machine maintenance needs

• Production Space Savings

– No space needed for case storage and curing



Properties Macromelt

OM 652/657 Macromelt


OM 673/678

Color amber/black amber/black amber/black

Service temperature range in °C -40 to +100 -40 to +130 -40 to +140

Cold flexibility in °C -45 -30 -40

Application temperature range in °C +180 to +230 +200 to +240 +210 to +240

Shore hardness A 77 A 90 A 90

Adhesion properties e.g. on PA +++ ++ +

Elongation at break in % 400 400 400

Remarks UL94-V0 UL94-V0 UL94-V0

Three standard products on polyamide basis

– For different service temperature ranges

– Each available in amber and in black color • Other grades are available and dependent on your application

Standard Product Ranges



Order information for direct Active Technology customers

Active Technologies Ref Color Packaging Active Technologies Order

Ref

Macromelt OM 652 Amber 20 kg bag ATO-M Melt 652

Macromelt OM 657 Black 20 kg bag ATO-M Melt 657





Macroplast CR6127 white-light-beige 35 kg Drum ATO-M Pott CR6127

Macroplast CR6127 SB15 black 35 kg Drum ATO-M Pott CR6127 SB15

Standard Product Ranges – Order Information

2.0 Kg Samples are available from Active Technologies, please request a quote.



Properties Macromelt

OM 653 Macromelt

6208/6208 S Macromelt


OM 648

Color amber amber/black amber/black black

Service temperature range in °C -40 to +100 -40 to +100 -40 to +130 -40 to +130

Cold flexibility in °C -50 -40 -35 -30

Application temperature range in °C +180 to +230 +180 to +230 +200 to +240 +200 to +240

Shore hardness A 77 A 82 A 92 A 93

Adhesion properties e.g. on PA +++ +++ Properties +

Elongation at break in % 400 600/450 650 550

Remarks - UL94-V0 UL94-V0 -

Four innovative products on polyamide basis

New Innovative Product Ranges



Product Name Color Packaging Active Technologies

Ref

Macromelt OM 653 amber 20 kg bag ATO-M Melt 653

Macromelt 6208 amber 20 kg bag ATO-M Melt 6208

Macromelt 6208 S black 20 kg bag ATO-M Melt 6208S

Macromelt OM 641 amber 20 kg bag ATO-M Melt 641

Macromelt OM 646 black 20 kg bag ATO-M Melt 646

Macromelt OM 648 black 20 kg bag ATO-M Melt 648

New Innovative Product Ranges – Order Information

Order information for direct Active Technology customers



Case Studies



Product Case Studies - Product Examples

• ATO-M customer applications have been developed using a range of over-moulded product solutions / techniques.

Encapsulation Encapsulation / Strain Relief PCB Protection / Strain Relief

PCB Protection / Strain Relief PCB Protection / Adhesion PCB Protection / Adhesion Encapsulation



Product Case Studies

Existing Product Examples

• Over moulded case studies



Product Case Studies - Existing Product Examples

• Over moulded case studies



Automated Custom Integration System Custom Manufacturing Solutions Full System Integration Solution High Volume Parts Med / High Cost Tooling High Complexity Part

Automated Machine Single or Dual Slide Design (Linear)

Multi Cavity (Rotary) Integrate Systems (i.e. EOLT, AOI)

Med / High Volume Parts Med / High Cost Tooling

Med / High Complexity Part

Hand Operated Semi Automated Machine Single or Dual Slide Design (Linear) 2-8 Cavity (Rotary) Low / Med Volume Parts Low / Med Cost Tooling Low / Med Complexity Part

A Hand Held Machine

Low Volume Parts Low Cost Tooling

Low Complexity Part Simple Solutions

Production Volumes

Time to Supply Equipment Cost

ATO-M Range L200 / R300

ATO-M Range M100 / M102

ATO-M Range AL1000 / AR2000

ATO-M Range C

<50

- 2

50

≈25

0 –

10

0K

≈10

0K

-

Mill

ion

(s)

<£3K* ≈2-4wks

<£30K* ≈6-8wks

<£77K* ≈10-14wks

*Cost & Time estimated & subject to change and complexity of product design

constraints Quotations available upon request

Product Guide

Cu

sto

me

r

Spe

cifi

c

Customer Specific



If you have any further requirements please contact Active Precision

Hethel Engineering Centre

Chapman Way, Hethel

Norwich, Norfolk UK

NR14 8FB

t: +44 (0) 1953 859133

e: [email protected]

atprecision.co.uk

Mr Paul K Edwards Over Mould Business Development Manager

(t) 07720 593511 [email protected]

Mr Michael Pickles Senior Sales Manager

(t) 07850 208796 [email protected]

Active Technologies Contacts








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