Low pressure moulding solution streamlines manufacture and extends scope for automotive sensors

Citation

(2005), "Low pressure moulding solution streamlines manufacture and extends scope for automotive sensors", Microelectronics International, Vol. 22 No. 3. https://doi.org/10.1108/mi.2005.21822cad.005

Low pressure moulding solution streamlines manufacture and extends scope for automotive sensors

Low pressure moulding solution streamlines manufacture and extends scope for automotive sensors

Keywords: Sensors, Automotive industry, Manufacturing

Macromelt®, from the electronics group of Henkel, is a low-pressure moulding solution for fast and convenient packaging of vehicle sensors. By replacing conventional sensor enclosures that require potting, Macromelt reduces the complexity, time and cost to assemble the large number of sensors now required by modern vehicles (Plate 1).

Macromelt is a material and process solution that simultaneously encapsulates the sensor's circuitry and forms the outer shell of the component to enable a self-contained and highly integrated component. The composition of the Macromelt moulding material, a polyamide hotmelt is available in a variety of formulations meeting the desired product and process requirements of numerous applications.

Plate 1 Macromelt®

The process requires a melt unit, low pressure dispensing system, and a mould. The mould is typically CNC-machined into aluminium, and can be produced on a faster turnaround than conventional injection moulds. This is critical to Marcomelt's advantage as a flexible and fast packaging solution for numerous diverse components. The low pressure exerted allows highly miniaturised features including fine-gauge interconnects to be encapsulated. The dispensing system for this low pressure process is relatively small, inexpensive and easy to operate: a force of only a few Newton is required, depending on the size of the component. Also the cycle time is short due to the rapid curing by cooling of the thermoplastic material.

Macromelt is compatible with a wide range of vehicle sensors and highly miniaturised door-handle electronics as well as new technologies such as intelligent battery sensors and screen- mounted antennas with integral cable stress relief. Pre-moulded connectors and sealed units plus grommets and strain relief components can also be manufactured quickly at competitive cost using Macromelt low pressure moulding.

Macromelt is available in translucent amber or black, as standard, with a variety of colours available to special order. The material is resistant to fluids commonly found in automotive environment such as antifreeze, petrol or diesel and hydraulic fluid. The operating temperature range can be optimised for a particular application by adjusting the composition of the low viscosity polyamide Macromelt material. It is possible to produce sensors for body applications, capable of operating from - 40°C to + 150°C.

For more information on Macromelt, visit the Henkel website at: www.electronics.henkel.com.