1of2_Adhesives Coatings and Encapsulants Product Training Aug 28 2008
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Transcript of 1of2_Adhesives Coatings and Encapsulants Product Training Aug 28 2008
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Company Confidential
Adhesives, Coatings and Encapsulants Electronic Materials Training
September 4-5, 2008Jason Sanders
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Meeting Title, DateCompany Confidential
INDIANAPOLIS FACILITY PROFILE
•90,000+ Square Foot Facility on 7 acres Located In Indianapolis, Indiana - USA–Manufacturing–60 Employees–2 Overlapping Shifts–12 Million Pounds Produced Annually
•TS 16949 and ISO 9001 registered•ISO 14001•Consolidated EW, PC and FV Manufacturing, Structural Adhesives Mfg.
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Company Confidential
Automotive ElectronicApplications
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Meeting Title, DateCompany Confidential
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Meeting Title, DateCompany Confidential
Encapsulants, Adhesives and Coatings
Lord Expertise and Capabilities
– Experience in supplying products for automotive electronic applications for over 30 years.
– Electronic materials available in three chemistries; epoxy, urethane and silicone.
– Materials application and electronics reliability test equipment to support product development
– Flexible manufacturing from bulk containers to syringes.
– Global manufacturing and technical support
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Meeting Title, DateCompany Confidential
Encapsulants, Adhesives and Coatings
Potting and encapsulating materials for:– Electronic ignition and engine control modules– Ride level and wheel speed sensors– Tire pressure sensors– Lighting ballasts and HID lighting– Capacitors, switches, connectors and relays– DC/DC converters– Circuit boards– Engine/transmission controller
Adhesives and Conformal Coatings for:– Lid sealing– Circuit board component assemblies– Battery Assembly– Radio boards
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Meeting Title, DateCompany Confidential
Encapsulants, Adhesives and Coatings
Currently Supplying Delphi with…..• Thermally Conductive Adhesive MT-220
• Epoxy Lid Seal Adhesive EP-870
• Silicone Lid Seal Adhesive SC-242
Current Programs at Delphi• Pencil-Type Ignition Coil – Epoxy ES-111
– Approved at Torreon, MEX, Seixal, – Portugal, Korea, China
• DIS Ignition Coil – Epoxy ES-110– Approved at Anderson, IN
• Truck Ignition Coil (Gen III, Gen IV, L6, DCX) –Epoxy ES-115
– Approved at Anderson, Torreon & Seixal
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Meeting Title, DateCompany Confidential
Currently Supplying Other Automotive Electronics Manufacturing Companies….
• Silicone EncapsulantsSC-300M, SC-316, SC-319
• Silicone Conformal CoatingsSC-2002 HV, SC-318
• Silicone Thermal AdhesivesSC-253, MG-122
• Silicone Lid Seal AdhesivesSC-212, SC-254, SC-412
• Silicone Thermal GreasesSG-21, SG-26, Circalok 6754
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Meeting Title, DateCompany Confidential
Currently Supplying Other Automotive Electronics Manufacturing Companies….
• Urethane EncapsulantsUR-312, UR-323, UR-325, UR-329
• Urethane Lid Seal AdhesivesCircalok 6404
• Epoxy Encapsulants302, 340, Circalok 6059, EP-809EP-830, ES-26U, ES-106, ES-95
• Epoxy Lid Seal AdhesivesES-90, ES-107
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Meeting Title, DateCompany Confidential
AUTOMOTIVE INDUSTRY QUALIFICATIONS
1. Air Bag SensorToyota, Ford, ChryslerEP-669, 302/#60, UR-278-5
2. Halogen Headlamp EncapsulantBosch - DC-23
3. Radiator AdhesiveVisteon - EP-701
4. Alternator Bridge RectifierGeneral Motors SC-254, EP-592, EP-593, EP-540
5. Battery AdhesiveGeneral Motors, Ford, Chrysler, Johnson Controls, EnertecEP, 433, EP-672, ES-38, ES-73
6. Hall Effect SensorGeneral Motors – UR-172, EP-830Ford, Chrysler – 300, EP-930, #67, #64AEC – SC-316
7. Radio Board CoatingChryslerSC-2002HV
8. Alternators – Starter MotorsDelco Remy -- RemanEP-445, EP-446, EP-447
9. SCAP SensorVisteon – UR-164Motorola – UR-285
10. Speed Control SensorVisteon – SC-253, ES-41, ME-138
11. Exhaust Re-circulation ControlVisteon, General Motors – EP-936
12. Electronic Spark ControlVisteon – SC-212
13. Electronic Ignition – After MarketFord – DC-23Chrysler – EP-680Flight Systems – CK-6055
14. Voltage RegulatorGeneral Motors – SC-139Chrysler – EP-680Robert Bosch – DC-23Transpo – CK-6700
15. Neutral Back–Up SwitchGeneral Motors – UR-212
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Meeting Title, DateCompany Confidential
AUTOMOTIVE INDUSTRY QUALIFICATIONS
16. Mass Air Flow SensorGeneral Motors – EP-139 Visteon – ME-138, SC-242, EP-903, EP-870, MH-205Hitachi – EP-729
17. Ignition CoilVisteon DIS – EP-697FVisteon E-Core – DC-812Chrysler, Honda – EP-760U, EP-929Shenda Motors – ES-44Bobinadores Unidos, Standard Motor Products, Echlin – EP-809Wells Mfg – ES-106Unison – EP-954Weastec – EP-760U, ES-26
18. Linear Position SensorFord – UR-190, UR-312
19. Brake Fluid Level DetectorChrysler, General Motors - 300#75
20. Transmission SensorChrysler – PR-30, ES-100, MT-220
21. Exhaust Leak Detector PumpChrysler, General Motors – UR-310
22. Engine Control ModuleChrysler – UR312, SC-300MThunder Heart Performance – UR-324Kimball – SC-254, SC-294
23. Fluorescent Lighting BallastFord – UR-212
24. ABS Wheel Speed SensorChrysler – EP-900#67Tractor/Trailer – UR-190
25. Auto Select Transmission ControlTractor/Trailer – UR-190
26. Windshield Washer Reservoir MotorGeneral Motors – EP-373
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Meeting Title, DateCompany Confidential
AUTOMOTIVE INDUSTRY QUALIFICATIONS
27. Windshield Wiper MotorGeneral Motors – 300/#25
28. Audio Power AmplifierChrysler – UR-310
29. Heated - Side View MirrorsGentex – CK6404Magna Donnelly – CK-6403
30. ABS – Electronic Control ModuleDelphi – MT-220
31. Oil Temperature SensorHi-Stat – CK6754
32. Electrical Steering ModuleEaton Corp. – UR-190
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Meeting Title, DateCompany Confidential
VACUUM PRESSURE AND IMPREGNATION
VPI Materials for:• Automotive ignition coils• Alternator and starter windings• Television fly-back coils• Aircraft ignition coils• Electrical and electronic applications• Power supplies
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Meeting Title, DateCompany Confidential
AUTOMOTIVE IGNITION COIL QUALIFICATIONS
Customer Application Product
Delphi Corporation DFI, DIS, COP and Pencil Coils Epoxy EncapsulantES-110, ES-115
Visteon Automotive Systems DIS and Pencil Coils Epoxy Encapsulant EP-697F
Wells Manufacturing After-market Ignition Coils Epoxy Encapsulant ES-106
Automotive Controls After-market Ignition Coils Epoxy Encapsulant EP-809
Standard Motor Products After-market Ignition Coils Epoxy Encapsulant EP-809
Weastec, Inc. OEM Coils – Chrysler, GM and Honda
Epoxy Encapsulant EP-760U, ES-26U
Walbro Engine Small Motor Coils Epoxy Encapsulant EP-809
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Meeting Title, DateCompany Confidential
Ignition Coil Encapsulants
• Epoxy/Anhydride Chemistries
• 40 – 60 % Filled Systems
• Vacuum Impregnation Dispensing
• Automated Preheat, Dispense and Cure Lines
• Multiple Designs of Coils
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Company Confidential
Industrial ElectronicApplications
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Meeting Title, DateCompany Confidential
Encapsulants, Adhesives and Coatings Product Properties
– High temperature epoxy and silicones for harsh environment exposures.
– Low modulus urethane encapsulants for protection of delicate electronics.
– Low shrink, low stress epoxy encapsulants and adhesives for delicate electronics and harsh environments.
– Fast cure one-component epoxy and silicone encapsulants, adhesives and coatings.
– Unique hybrid epoxy-silicone and urethane-polyester chemistries.
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Meeting Title, DateCompany Confidential
Encapsulants, Adhesives & CoatingsProduct Selector Guide
Product Name Description Typical Applications Type1 or 2
Component
300/#72 Filled 1 to 1 Epoxy System Encapsulant for Electrical/Electronic Devices Epoxy 2340/#70 Thermally Conductive Epoxy System Encapsulant for Electrical/Electronic Devices Epoxy 2EL-636 Highest Temperature Resistant Epoxy System Encapsulant for High Temperature, 180° Requirments Epoxy 2EP-20/#65 Unfilled 2 to 1 Epoxy System Encapsulant for Electrical/Electronic Devices Epoxy 2EP-809 General Purpose Epoxy Coil Encapsulant Encapsulant for Ignition Coils Epoxy 2EP-830 High Tg Epoxy Encapsulant Encapsulant for Ignition Coils Epoxy 2EP-870 High Viscosity Epoxy One Component Electronic Modules/Lid Seal Epoxy 1EP-937 Medium Viscosity Epoxy One Component Encapsulant/coating for Electronic Devices Epoxy 1ES-73 Unfilled 1 to 1 Epoxy System Battery (Auto/Marine) Epoxy 2ES-86 Fire Retardant Epoxy System Encapsulant for Power Devices Epoxy 2ES-106 Economical, Epoxy Coil Encapsulant Encapsulant for Ignition Coils Epoxy 2SC-102 Unfilled 1 to 1 Silicone System Encapsulant for Electronic Devices Silicone 2SC-242 Primerless, Filled Silicone, One Component Encapsulant/Coating/Adhesive for Electronic Devices Silicone 1SC-253 Thermally Conductive Silicone System Adhesive for Power Components Silicone 2SC-254 High Strength Unfilled Silicone One Component Coating/Sealant for Alternator Silicone 1SC-294 Primerless Unfilled Silicone One Component Encapsulant/coating for Electronic Devices Silicone 1SC-300M Low Modulus 1 to 1 Silicone Gel Encapsulant for Electronic Modules Silicone 2SC-308 Low Tg Thermally Conductive Silicone Encapsulant for Power Devices Silicone 2SC-309 Low Viscosity Thermally Conductive Silicone Encapsulant for Power Devices Silicone 2SC-2002HV Low Viscosity One Component Silicone Conformal Coating for Circuit Board Silicone 1UR-312 Low Modulus Urethane Gel Encapsulant for Electronic Modules Urethane 2UR-322 1 to 1 Unfilled Urethane Systems Encapsulant for Electrical/Electronic Devices Urethane 2UR-325 High Strength Urethane Encapsulant Encapsulant for Electrical/Electronic Devices Urethane 2UR-340 Economical, Urethane Encapsulant Encapsulant for Electrical/Electronic Devices Urethane 2
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Meeting Title, DateCompany Confidential
Manufacturers of Power Converters
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Meeting Title, DateCompany Confidential
Manufacturers of Instrument Transformers,Metering Devices and Peripherals
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Meeting Title, DateCompany Confidential
Manufacturers of Power Supplies,Charging Devices, Marine Accessories
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Meeting Title, DateCompany Confidential
Manufacturers of Cast Coils andHigh Voltage Commercial Transformers
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Meeting Title, DateCompany Confidential
CONSUMER ELECTRONICS
• Power Transformers
• Pumps (Submersible & Ambient Operations)
• Surge Suppressors
• Relays
• Ignition Devices
• Heating Elements
• Typically Require Compliance to Underwriters Laboratory Certification
• Component vs. Material Compliance
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Meeting Title, DateCompany Confidential
Regulatory Issues
• Directive 2002/95/EC of the European Parliament• RoHS - Restriction of Hazardous Substances Directive• WEEE – Waste Electrical & Electronic Equipment Directive• Address EU Disparities in Hazardous Substance Regulation• Targets Lead,Cadmium,Mercury, Polybrominated FR
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Meeting Title, DateCompany Confidential
Application Chemistry
Parameter Urethane Epoxy SiliconeCost Moderate Moderate HighProcessing Most Difficult Best ModerateOperating Range -50°C to + 105°C -40°C to + 130°C -120°C to + 200°CRepairability Good Poor ExcellentAdhesive Strength Moderate High LowModulus Moderate High LowChemical Resistance Moderate High LowElectrical Insulation Good Excellent ExcellentDielectric Constant Moderate Moderate Low
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Company Confidential
Epoxies
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Meeting Title, DateCompany Confidential
Epoxies for E/E Applications
Excellent electrical properties Good adhesion due to presence of polar groups Low shrinkage Good impact resistance Superior Moisture & Chemical resistance
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Meeting Title, DateCompany Confidential
Epoxy EncapsulantEP-20 Resin
• Industry Standard, Two Component, RT or Heat Cured
• Black, Unfilled Epoxy Resin
• Available with Multiple Hardeners
Typical Application – Small Switches, Relays, Sensors
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Meeting Title, DateCompany Confidential
EP-20 Resin Product LineNo. 18 No. 66 No. 65 No. 67 No. 71
Mix Ratio (resin to hardener)By weight 100:14 Variable 100:40 100:24 100:100By volume 100:16 Variable 100:50 100:30 100:120Mixed Viscosity @ 25°C (cps) 3,200 30,000 1,200 2,000 3,000Working Life @ 25°C 20 min 75 min 50 min 60 min 60 min
(100g) (400g) (200g) (200g) (200g)Typical Cure Schedules 24 hrs 24 hrs 24 hrs 2 hrs 24 hrs
@25°C @25°C @25°C @100°C @25°C
Physical Properties:Hardness (Shore D) 88 82 85 92 60ASTM D 2240Specific Gravity @ 25°C 1.04 1.06 1.09 1.11 1.08
Temperature Rating Guide* 130°C 105°C 130°C 155°C 130°CTensile Strength (psi) 11,200 7,500 9,000 10,900 2,300Tensile Elongation 3.6% 4.5% 4.5% 5.2% 55%Izod Impact Strength (ft lb/in) 0.38 1.50 0.55 0.32 2.50Water Absorption (24 hours) 0.18% 0.35% 0.22% 0.20% 0.85%
Electrical Properties:Dielectric Constant 3.9 3.7 4.2 4.4 4.2Dissipation Factor 0.02 0.016 0.016 0.038 0.021Volume Resistivity (ohms/cm)
@ 25°C 1015 1015 1015 1016 1014
@ 105°C 1013 1011* 1011 1014 1010
@ 130°C <1010 <109 <109 1013 109
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Meeting Title, DateCompany Confidential
Epoxy Encapsulant300 Resin
• Industry Standard, Two Component, RT or Heat Cured
• Black, Silica-filled Epoxy Resin
• Available with Multiple Hardeners
Typical Application – Transformer Encapsulant, Power Supplies