LT-4182 Macromelt - Loctite.ph

Low Pressure Molding
Macromelt ®

LOW PRESSURE INSERT MOLDING
Henkel, the global leader in adhesives, and The Cavist Corporation, application engineering and equipment experts in the field of low
pressure insert molding, have partnered to offer a complete solution for the gentle over-molding and encapsulation of delicate
electronic components.
Low pressure molding is an innovative manufacturing process between injection molding and potting. It is injection molding at very low
pressures with hot melt adhesives. It is a cost effective alternative to epoxy potting for protection of fragile electronic components. When
used for cable and connector molding, it offers superior strain relief compared to conventional plastic injection molding.
Process Flow Advantage of Low Pressure Molding
TRADITIONAL POTTING PROCESS FLOW
LOW PRESSURE PROCESS FLOW
The Low Pressure Molding process
provides many benefits.
• Complete sealing of the components,
providing water-tight encapsulation
• Effective strain relief
• Low viscosity materials allow for low
injection pressures of 20 to 500 psi
• Allows gentle pre-molding of connectors
• Components and wires are not
damaged or dislocated in cavities
• Easy to encapsulate fragile components
• No hazardous fumes from
materials or processing
• Short (15-45 seconds) cycle time to
complete part

Headline “Overmolding replaces both the housing
Helvetica and potting Neue in just 75 Bold one operation.”
20pt/25pt - tracking 3
Seal large PC boards with
external connectors
Encapsulation of sensitive
electronics prior to
conventional overmolding
Overmold various
electronic shapes
Packaging of sensitive
high performance electronics

“Adhesive Materials offer
superior strain relief.”
Mold strain relief and grommets
Seal multi-wire connectors
Mold connectors with strain relief
Superior strain relief for
modular connectors without
mechanical crimping
Seal micro-switches

HENKEL MACROMELT ® LOW PRESSURE MOLDING MATERIALS
Henkel is the world leader in high performance adhesive materials. The Macromelt ® OM line of low pressure molding materials are
innovative, specially-modified thermoplastic polyamide hot melts made especially for low pressure molding.
Macromelt ® products melt and flow at low viscosities (1,000 to 10,000 cps), allowing for the low injection pressure process. Macromelt ®
offers very good adhesion to various substrates, including PVC, PA6.6, PUR, and PP. Since they are based on adhesive technology, they bond
to form a watertight and chemical seal. These hot melts cure quickly by cooling so there are no toxic fumes and cycle times are short. The
entire line of Macromelt ® OM products is UL94-V0 rated. The materials are available in amber, black and custom colors.
MACROMELT ® DATA - Based on General Values
Properties Test Method Unit OM 633 / OM 638 OM 641 / OM 646 OM 652 / OM 657 OM 673 / OM 678 MM 6208 / MM 6208S
PHYSICAL
Color amber / black amber / black amber / black amber / black amber / black
Specific gravity DIN 53479, S S.G. 0.98 0.98 0.98 0.98 0.98
Working temperature Henkel Method °C -40 to +130 -40 to +130 -40 to +100 -40 to +140 -40 to +150
Hardness ASTM D 2240-85 Shore A 90 92 77 88 78
Elongation @ rupture ASTM D 638-00 % 400 800 400 500 600
Softening point, ASTM E 28-99 °C 175 175 155 187 / 185 150 – 160
Ball & Ring
Molding temperature Henkel Method °C 200 to 240 210 to 240 180 to 280 210 to 240 190 to 230
Viscosity @ 210°C ASTM D 3236-88 mPas 3700 7000 4100 3400 3600
ELECTRICAL
Dielectric ASTM D150-95 4.5 / 4.7 5.1 / 5.5 6.2 / 6.3 4.9 / 4.9 6.1 / 6.3
constant @ 1 kHz
Volume resistivity D257-93 Ohm cm 1.7E15 / 2.4E13 6.3E12 / 1.7E12 1.0E12 / 7.2E11 1.90E12 / 1.90E12 1.9E11 / 1.6E11
Dielectric strength ASTM D149-97a kV / mm 24 / 19 25 / 22 14 / 15 20 / 20 23 / 23
RATINGS & TEST RESULTS
FDA category FDA Adhesives 175.105 (OM 633) 175.105 (OM 641) 175.105 (OM 652) 175.105 (OM 673) 175.105 (MM 6208)
Flammability rating U/L 94 V-O V-O V-O V-O V-O

Henkel Corporation
Irvine, California
U.S.A.
www.electronics.henkel.com
Henkel –
Your partner worldwide
The Cavist Corporation specializes in low pressure molding. The low
pressure molding system requires careful engineering of the mold-set to
achieve consistent, high volume production. This process allows you to
utilize cost effective aluminum mold-sets. Either single or multi-cavity
mold-sets can be used. Cavist is the low pressure molding supplier of:
• Quality application
engineering
• Mold-set fabrication
or guidance to create
your own mold-sets
• Prototyping
The Moldman Low Pressure Injection Molding Technology is the best
equipment for dispensing Macromelt ® quality component.
Molding materials to create a
• High capacity • User friendly and safe
• Small footprint • Injection profiles
• Simple to operate • Made in U.S.A.
• Easy set-up with
touch screen
The Cavist Corporation
3545 Airway Drive #112
Reno, NV 89511 U.S.A.
775-332-1600 • Fax 775-332-1601
www.cavist.com • mail@cavist.com
Henkel Corporation
15350 Barranca Parkway
Irvine, CA 92618
949-789-2500 • Fax 949-789-2595
www.electronics.henkel.com
• Molding equipment
incorporating the latest
Nordson Corporation melt units
• Contract molding services
® and designate trademarks of Henkel Corporation or its Affiliates. ® = registered in the U.S. and elsewhere.
© Henkel Corporation, 2005. All rights reserved. 2894/LT-4182 (4/2005)