Apr 23, 2010 
As a robust alternative to traditional potting and encapsulation techniques, Macromelt’s outstanding performance has been proven time and time again. The automated processing, throughput and cure time advantages Macromelt delivers simply can’t be matched by older-generation encapsulation methods. Use of the material dramatically reduces the number of process steps required as compared to conventional potting, while also reducing the cost and complexity of the encapsulation process.
Now, Macromelt has been extended with the addition of Macromelt OM341 for the hybrid automobile market and Macromelt 2384 for the medical electronics sector. With this advance comes the selection of Macromelt OM341, along with traditional Macromelt materials, for use in one of the Big 3 automakers’ latest hybrid vehicles. After a six month formulation development effort, 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 3 US automakers.”
Not only will Macromelt OM341 be used for easy identification and access to the main power connector for a new hybrid vehicle, but other Macromelt formulations will also be 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, CCID board and the vehicle plug for the travel set and charge station.
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 of the performance or ease of use benefits associated with the established Macromelt brand. The polyamide hotmelt quickly encapsulates exposed circuitry to form the outer shell of the device and delivering a self-contained integrated assembly. With a low application pressure of between 20 to 500psi within the mold cavity, there is no risk of damage to sensitive circuitry or fragile devices. When in a liquid state, Macromelt flows in and around the tightest dimensions without the high levels of pressure used with traditional injection molding or potting techniques and significantly reduces stress even for the most highly miniaturized components.
“Henkel’s commitment to innovation is clearly evidenced in these latest Macromelt formulations,” concludes Pierce. “I don’t know of many suppliers who would have exhibited the persistence necessary to develop the safety orange Macromelt material -- we have once again proven our innovative leadership with this most recent solution for the hybrid automobile market.”
For more information regarding the advantages that Macromelt technology can provide, log onto http://www.henkel.com or call 1-888-9Henkel.
Except as otherwise noted, all marks used herewith are trademarks and/or registered trademarks of Henkel and/or its affiliates in the US and elsewhere.
About Henkel
Henkel has been committed to making people's lives easier, better and more beautiful for more than 130 years. A Fortune Global 500 and Germany's most admired company according to a recent Fortune survey, Henkel offers strong brands and technologies in three areas of competence: Home Care, Personal Care and Adhesive Technologies. Each day, about 50,000 employees worldwide are dedicated to fulfilling Henkel's claim "A Brand like a Friend”. In fiscal 2009, Henkel generated sales of 13,573 million euros and adjusted operating profit of 1,364 million euros.
