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									                Macromelt Chosen for Next Gen Hybrid Vehicle
                    Popular Low Pressure Molding System Ideal for
                   Green & Portable Energy and Medical Applications
                              by Michael Pierce, Henkel

Already well known as a viable alternative to traditional potting materials and processes,
the robust Macromelt low pressure molding solution from Henkel is now making huge
inroads with applications for the green and portable energy and medical electronics
sectors. The streamlined processing is certainly a factor for Macromelt’’s widespread
adoption, but its exceptional performance and ability to meet some strict requirements
has accelerated its acceptance, particularly in the hybrid automotive market.

                                                      Macromelt is a low pressure
     Traditional Macromelt                            molding system that replaces
                                                      traditional injection molding or
                                                      potting. The polyamide hotmelt
                                                      provides a fast and convenient
                                                      packaging solution that both
                                                      encapsulates the circuitry and forms
                                                      the outer shell of the device,
                                                      delivering     a      self contained,
                                                      integrated assembly.         Use of
                                                      Macromelt      also      dramatically
                                                      reduces the number of process steps
required by conventional potting and reduces the manufacturing time, cost and
complexity of the encapsulation process. Macromelt’’s low viscosity is key to the success
of the molding process. With an application pressure of between 20 to 500psi, the low
pressure in the mold cavity does not risk damaging the sensitive electronic surface
mount components. The hotmelt polyamide adhesive is able to flow around the tightest
dimensions without the high levels of pressure required by traditional materials,
significantly reducing stress even for highly miniaturized components.

Taking these advantages and extending them to address the unique requirements of the
hybrid automotive sector, Macromelt OM341 has been formulated with a new color ––
safety orange –– and was chosen by one of the Big Three Automakers for use with key
components in their vehicle. The development effort for this material was intense as
color variations can impact viscosity. But, after a six month formulation process, the
Macromelt team was rewarded with a huge win.

““Developing the safety orange colored Macromelt OM341 was no easy feat””, explains
Henkel’’s Michael Pierce. ““After nearly 60 different modifications, we finally hit color,
viscosity and UV stabilization perfection. And, our perseverance helped further our
partnership with a major supplier to one of the Big Three US automakers.””
Not only is Macromelt OM341 being used for easy identification and access to the main
power connector for the new hybrid vehicle, but other Macromelt formulations are also
part of the vehicle’’s electrical sensor system, as the popular hotmelt brand is being used
for seven different components within this automobile. These include the main
electrical outlet, seatbelt tension sensor, occupancy sensor, steering position sensor,
strain relief receptacle and base, and the vehicle plug for the travel set and charge

The UV stabilization chemistry used in the safety orange Macromelt OM341 ensures
that the color remains vibrant, easily identifiable and will never discolor from exposure
to UV light. This same UV stabilization characteristic, along with new solvent resistant
technology, has also been incorporated into Macromelt materials employed by the
medical industry. Used to encapsulate numerous medical monitoring devices,
Macromelt 2384 is highly solvent resistant, which resolves the sterilization dilemma
many medical manufacturers face with alternative materials.

What’’s more, all of these new
formulation advances have been
developed without altering any                                       Macromelt OM341
of the performance or ease of
use benefits associated with the
established Macromelt brand.

These latest Macromelt systems
are just further evidence of
Henkel’’s    commitment      to
innovation and the company’’s
perseverance when it comes to
enabling customer processes.
There likely aren’’t too many
suppliers that would have
undertaken such an intense development process, but Henkel delivered.

For more information on Macromelt portfolio of products, including Macromelt OM341
and Macromelt 2384, contact Henkel at 949 789 2500 or watch the video at video 30850.htm .

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