electrical and electronics | Applications
activated LCP to manufacture miniature LED lighting elements for customer KaVo Dental using laser direct structuring technology. The Vectra LED bases are injection moulded on an
Arburg Allrounder 220 moulding machine, followed by a selective lasering process that “activates” the polymer surface where the electrical circuits are required. The copper circuitry is then applied by electroless deposi- tion and the electronic components applied and soldered prior to assembly of the base with the injection moulded lens and housing. US-based Radiall has switched from machined PTFE
Above: Delphi selected DSM’s Stanyl for this ignition coil connector
reduces manufacturing cost. To ensure maximum reliability of the seal, Bosch
engineers decided to use an “inside-out” manufactur- ing process that involved first production of the 4mm high internal TPE seal, then over-moulding of the polyamide body, followed by moulding of the external soft touch TPE grip and logo elements. A rotary mould was used for the project. The seal – which prevents dust and debris accessing
and grease escaping from the hammer mechanism – adheres directly to the PA body material during the moulding process, which minimises risk of displace- ment or incorrect assembly. Kraiburg optimised the compressive properties of the TPE for the application. Automotive components group Delphi Automotive
Right: Bosch moulds the TPE seal first in this power tool housing
Systems has approved DSM Engineering Plastics’ Stanyl TW200F6 grade for production of an over-mould- ed connector that is soldered to the ignition coils it supplies to a number of European car manufacturers. Manufactured by Delphi Portugal, the ignition connector is produced by over-moulding the metal inserts in a rotary mould. After assembly on the coil, the connector surface is plasma pre-treated and the connector potted with epoxy. Delphi selected Stanyl for the application for
its high temperature resistance, mechanical performance and ability to withstand the wave soldering technique used during assembly. The TW200F6 resin is also said to provide higher crystallin- ity and faster crystallisation rates than PA6, PA66, polyesters and other high heat resistant resins such as PPA, PPS and LCP, which improves manufacturing economics.
German specialist electronics component maker 2E-Mechatronic is using Ticona’s Vectra E840i laser-
16 INJECTION WORLD | September 2012
www.injectionworld.com
to injection moulded PEEK resin from Victrex to manufacture the miniature insulators fitted to its SMPM range of snap-on connectors it supplies for military and aerospace communications applications such as antennae and radar. The company adopted the miniature PEEK insulator – which measures less than 2mm in diameter - to overcome reliability issues resulting from creep of the PTFE components. The company has also benefited from the better thermal stability of PEEK, which means it is less likely to suffer damage during soldering and assembly in the beryllium copper and stainless steel connector housings. New technologies such as electric vehicles, LED lighting and photovoltaics are presenting new opportu- nities for plastics. DuPont has been working with Japanese electric vehicle technology developer SIM-Drive in development of its new distributed drive system, which was launched earlier this year. The technology combines the use of lightweight structures with “in-wheel” motors to create a vehicle capable of speeds up to 180km/h. The bobbins for the motors – designed to be installed
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