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HOT MELT RESIN MOLDING TECHNOLOGIES

SYSTEM'S STRUCTURE

Suitable Mold Project and Realization

Correct Molding EquipmentRaw Material in compliancewith the requirements ofthe finished product

MECATRONIC offers a complete service that includes:

Mold for sampling and/or production

Clamping system depending from the product

Production starting assistance

Project coordination for the correct materials choice

Molding Quality


WHAT IS IT THE HOT MELT MOLDING SYSTEM?

SOLUTIONS FOR ELECTRONIC AND CABLING WORLD

The widespread use of micro-electronics in the automotive and electronics industry, inparticular of the miniaturization and of modularization of components, makes necessary topay special attention to the protection of the individual parts.

The reason why it is necessary to use peculiar protection for electrical and electronic parts(LEDs, relays, switches) is to protect them from heat, moisture, dust, mechanics impact toguarantee long operation.In order to make these protections injections of PVC or standard POLYAMIDES can beused, but the high pressure (greater than 300 bar) used in these processes can damagesensitive components.

HOT MELT molding technology offers an alternative of small, medium and large quantitiesof productions. This technology uses low pressure (2-25 bar), which also allows the use ofsimple aluminum molds at low cost.The injection into the mold is carried out by special valves that control the volume of resinto be injected.

The materials used in the hot melt have a good adhesion on many materials, do notgenerate gas, they are water resistant and overprintable.

There are only a few thermoplastics used in tank whose characteristics depend frommolding project needs and from technical specifications related to it.


ADVANTAGES OF HOT MELT TECHNOLOGIES

MOLDING DONE AT LOW PRESSURE

Simple aluminum molds at low cost No demage to the components caused by high pressure Very low viscosity of the molding materials

LOW TEMPERATURE PROCESSING

Short cooling times Low stress due to temperature on the components

POSSIBILITY TO USE DIFFERENT TYPE OF HOT MELT (OF COPOLYAMIDES)

Good adhesion on different types of material HOT MELT polyamide materials are environmentally-friendly Pleasant appear of printed surface

ECONOMY

Possible short cycles Economy molds Quick and easy replacement of the molds Molded parts not removable

ECOLOGICAL FACTORS

No solvents or other toxic substance It is not necessary to clean the molding unit after use No chemical reactions

MACHINERY

Compact machine Easy-to-use Modular equipment modular and configurable Simple in-line connection

INCLUDED SERIVICES

Specific equipment Fast supply of materials and equipment Excellent maintenance service


TM2000Low Pressure Molding System

Gun for polyamide resins


DESCRIPTION

TM2000 manual gun is an electronically controlled tool for working with polyamide resins suitablefor laboratory tests or miniseries. TM2000 can be equipped with the optional columnar holder.

FEATURES

Quick tank refilling Consistent amount of resin can be injected Low pressure operating Low cost moulds Temperature check with Led indicator

Technical specifications

Operating temperature: adjustable from 50° C to 245° C.Temperature check display: electronic/digital +/- 1° CCapacity check system: compressed air from 1.5 to 5 BarPower supply: 230 V/50 HzTank capacity: 300 gramsAmount of injectable resin: 2.5 Kg/hDimensions: 335 x 65 x 320 mm

CE-conformity: TM2000 fully complies with all CE and EMC equipment guidelinesrelative to mechanical and electrical safety and electromagneticcompatibility.

Important: Mecatronic recommend to submit wire samples in case of doubt aboutthe processing capabilities of a particular machine.

Technical specifications are subject to change according to possible needs and without notice.


JET MELT TECHNOLOGY™-THERMOPLASTICS INSERT INJECTION MOLDING-

BENEFITS

No carbonization

Precise and repeatableinjection volume

Quick color change

Use of granulates loaded withadditives

Fully automatic cycle

Low consumption of energy

Parameters recording

Thermoplastic and Hot melt insertion unit


DESCRIPTION

The JET MELT is a low / high pressure Thermoplastic and Hot melt insertion unit

Further system benefits

Positioning with horizontal injection andsliding plate for mould die

Integrated electronics, user interface withkeyboard and LCD back lighted display


Program memory: 10 programs (optional) Plasticizing screw and piston injection unit Injection controller in volume operated by encoder Use of heated, not-heated and either open or closed type direct input nozzles Built-in collar cooling unit PID system 8 level temperature adjusting In flow injection speed adjusting Pressure adjusting with 0.1 bar tolerance Granulate automatic feed (Venturi system in option) RS232 interface Noiseless cycle Low maintenance costs

Programmable parameters

4 heating areas with surveillance alarm Injection: Time (res. 0.1 sec.), Pressure (res. 0.1 bar), Injection speed (res. 1 turn) Post-pressure (cushion): Stroke (mm), Pressure (bar), Time (sec.) – general resolution 0.1 Reload: Stroke res. 0.1 mm, Speed res. 1 turn Press controls I/O and alarms Draw / Fixed / Sequential control 6 levels sequential injection with height and pressure programming Cooling time (sec.)

Hot Melt moulding features

Moulding of copolymers, polyester, polyolefin, polyamide, etc. Quick and easy change of colour and material (few minutes) Up to 50% moulding cycle reduction Reduction in waste of raw material Reusable feed heads

Moulds

Moulds with injection on the lower, central or upper split Single or multi impression mould (aluminium or steel) Integrated handling of hot chamber moulds (optional) Sliding or rotating multi moulds handling Pneumatic clamping unit with static locking Mould dimensions: max 200 x 200 x 150 mm Automatic pulling-out system (optional) Flask mould fixing system Mould conditioning system (optional)


Technical specificationsMoulding materials: high and low pressure copolyammide, polyester, polyolefin, pvc,

polycarbonate, etcInjection capacity: max 80 cc

Power supply: 380V / 16 A

Compressed Air: 7 Bar, dried, not oiled

Injection pressure: 0.1-400 barMoulding surface: max 20 cm²Dimensions & Weight: 1300x1800x1300 mm / 700 Kg approx. (version with slide)

900x300x900 / 160 Kg approx. (version with injector for transfer lines)

CE conformity: The Jet Melt Unit fully complies with all CE and EMC equipment guidelines relativeto mechanical and electrical safety and electromagnetic compatibility.

Important: Mecatronic recommends to submit samples in case of doubt about the processingcapabilities of the machine.

Side View



LOW PRESSURE MOLDING

This technology has drawn its origins in Europe by the automotive industry, but new applicationshave grown quickly in the fields of electronic control, data communications and home appliances.

Requirements

Connectors and circuits water-resistance Electrical insulation parts Mechanical protection against dirt and chemicals Temperature resistance Low flammability Neutrality chemical

Benefts

Processing: short cycles, immediate handling of molded parts, easy processing, cheapermolds,easy to calculate costs, no presence of fumes or solvents;

Molded parts: simple shapes, molded cables with different sections, encapsulated PCB withoutdamaging the components, noise and vibration reducing level, different colors.


500 A1

Melting tank with touch screen


FEATURES

Technical Specifications

Melting Tank Volume: 500A (5/10/15/20 liters)Installation Area: 400X 1760 mmTemperature Control Zones: 2 zonesTemperature Range: Ambient. To 230 °CPower Supply: 200-240 VAC / 50 – 60 Hz – max 4 KwAir Supply: 6 Bar 0.1m³ /minControl System: PLCControl Interface: Touch screen 5.7”Dimensions & Weight: 400 x 760 x 1050 mm / 63 Kg

CE Conformity: The 500A1 fully complies with all CE and EMC equipmentguidelines relative to mechanical and electrical safety andelectromagnetic compatibility.

Important Note: Mecatronic recommends that samples be submitted in caseswhere there is doubt as to processing capabilities.

High volume melting tank 5.7” Touch Screen Operator Interface with multi-language PLC Two thermal control zones for precise melt control Critical components (gear pump, valve and nozzle) are designed

for PA adhesive Injection pressure is adjustable from 1 to 5 bar The system can be connected to different injections guns or

working stations



BETA 600

Low PressureMolding System


DESCRIPTION

Horizontal injection system Single injection gun directly connected to gear pump Unique moving tank design, eliminates the melting hose User friendly multiple language PLC control OMRON and SMC components for reliability and international standards Economical two post die system for professional results with minimal investment Two PID thermal control zones Mechanical ejection system and control for pneumatic ejection Equipped with Light Curtain and Dual Palm buttons for operator safety The system can be tailor made for your local power supply


Working Station O.D. 740x700x1600 mmMelting Tank Volume: 3 literInstallation Area: 740x700 mmFrame: Aluminium extrusion, Chrome Plated SteelGuide Rods: 2 hard Chrome plating groundLinear Bearings: Precision recirculating ball bearingsGun type: LPMS-T1-3925-36/90-A 1 pcInjection Type: Single Station HorizontalAdhesive Delivery: LPMS-T4—8325-A 1 pcGear Pump Speed Control: InverterTemperature Control Zones: 2 zonesTemperature Range: Ambient. To 250 °CTemperature Accuracy: +/1 °CPower Supply: AC220 VACAir Supply: 6 Bar 0.1m³ /minClamping Device: Pneumatic CylinderClamping Force: 1.2 TDie space: max 180x100x150 mmClamping Stroke: 150 mmControl System: PLCControl Interface: Touch screen 5.7”Weight: 300 KgDimensions: 740x700x1600 mm (base: 840x1000mm)

CE Conformity: The BETA 600 fully complies with all CE and EMC equipmentguidelines relative to mechanical and electrical safety andelectromagnetic compatibility.

Important Note: Mecatronic srl recommends that wire samples be submitted incases where there is doubt as to processing capabilities of aparticular machine.



BETA 800

Low PressureMolding System


FEATURES


Working Station Height 900 mmMelting Tank Volume: 500B (5 liters)Installation Area: 1040X920 mmFrame: Aluminium extrusion, Chrome Plated SteelLinear Bearings: Precision recirculating ball bearingsGear Pump Speed Control: InverterTemperature Control Zones: 3 zonesTemperature Range: Ambient. To 230 °CTemperature Accuracy: +/1 °CPower Supply: AC220 VACAir Supply: 6 Bar 0.1m³ /minClamping Device: Pneumatic CylinderClamping Force: 1.2 TDie space: max 300x200x150 mmMax Part Size: 60x50x18 mmClamping Stroke: 150 mmControl System: PLCControl Interface: Touch screen 5.7”Weight & Dimensions : 1040x915x1660 mm / 350 Kg

CE Conformity: The BETA 800 fully complies with all CE and EMC equipment guidelinesrelative to mechanical and electrical safety and electromagneticcompatibility.

Important Note: Mecatronic recommends that samples be submitted in cases wherethere is doubt as to processing capabilities.

Vertical Injection System Single Injection Gun Compact design with melting tank integrated on the machine 5.7” Touch Screen Operator Interface with multi-language PLC Three Indipendent PID thermal control zones Mechanical ejection system and control for pneumatic ejection Omron and SMC components for reliability and international standards Equipped with Light Curtain and Dual Palm buttons for operator safety

standard molddimensions

max molddmensions



BETA 800M

Dual working station low pressuremolding machine


DESCRIPTION


Working Station Height: 890 mmPlant View: 1700x1300Melting tank model: 500 B (5 liter) x2Frame: Aluminium extrusion, Chrome Plated SteelLinear Bearings: Precision recirculating ball bearingsGear Pump Speed Control: InverterTemperature Control Zones: 6 zonesTemperature Range: up to 230 °CTemperature Accuracy: +/1 °CPower Supply: 200-240 VAC / 1 Phase / 50-60 HzPower comsuption Kw 8.8Air Supply: 6 Bar 0.1m³ /minClamping Device: Pneumatic CylinderClamping Force: 1.2 TDie space: max 300x200x150 mmMax Part Size: 60x50x18 mmClamping Stroke: 150 mmControl System: PLCControl Interface: Touch screen 5.7”Weight & Dimensions : 1300X7805X1650 mm / 540 Kg

CE Conformity: The BETA 800M fully complies with all CE and EMC equipmentguidelines relative to mechanical and electrical safety andelectromagnetic compatibility.

Important Note: Mecatronic recommends that samples be submitted in cases wherethere is doubt as to processing capabilities.

Vertical Injection System Dual Independent work stations Separate high volume melt tank 5.7” Touch Screen Operator Interface with multi-language PLC Up to 100 different working programs Mechanical ejection system and control for pneumatic ejection Omron and SMC components for reliability and international standards Equipped with Light Curtain and Dual Palm buttons for operator safety


MACHINE DIMENSIONS

MOLD DIMENSIONS

STD. MAX.




1. HOT MELT APPLICATIONS




500A1 Jet Melt Alpha-100 Alpha-200

Delta-1000 Delta-2000 Kappa-1000 Kappa-2000

Beta-500 Beta-600 Beta-700 Beta-800

TANK OPTION CONFIGURATION

OPZIONI PER FUSORI

CONFIGURAZIONE UNITA’ DI INIEZIONE

INJECTION SYSTEM

CONFIGURATION

MACHINE TYPE MODELLO MACCHINA ALPHA-100 ALPHA-200 BETA-500 BETA-500B BETA-600 BETA-700 BETA-800 BETA-800M DELTA-1000 DELTA-2000 KAPPA-1000 KAPPA-2000 500 A1

ON LINE INSTALLATION - Adatta per installazione in linea transfer xPORTABLE - Portatile xTABLE TOP - Da tavolo x xBENCH TOP - Da banco da lavoro x xSTAND - Con base di supporto x x x x x x x xHORIZONTAL INJECTION - Iniezione orizzontale x x x x xVERTICAL INJECTION - Iniezione verticale x x x x x x xMOVING TANK - Fusore traslante x x x xSEPARATE TANK - Fusore separato x x x x x x xINTEGRATED TANK - Fusore integrato con il gruppo di iniezione x x x x x xMELTING TANK VOLUME - Volume contenuto nel fusore 200 cc 1 lt 3lt 3lt 3 lt 3 lt 3 lt 5 lt*** 5 lt*** 5 lt*** 5 lt*** 5 lt*** 5 lt***PRESSURIZED TANK - Fusore in pressione x x

TEMPERATURE CONTROL ZONE - N° zone di controllo temperatura 1 ZN 1 ZN 2 ZN 2 ZN 2 ZN 3 ZN 3 ZN 5 ZN 6 ZN 9 ZN 3 ZN 5 ZN 2 ZN

POWER - Potenza 0,5 to 1,0 KW 2,0 KW MAX 1,5 to 3,5 KW 1,5 to 3,5 KW 1,5 to 3,5 KW 1,5 to 4,0 KW 1,5 to 4,0 KW 1,5 to 4,0 KW 1,5 to 4,5KW 1,5 to 6,0 KW 1,5 to 4,0 KW 1,5 to 4,0 KW 1,5 to 4 KW

CLAMPING MOLD SYSTEM - Sistema di chiusura pneumatico 310 Kg 730kg 730kg

730 kg for 125mm Ø air cylinder 1200 kg for 160mm Ø air cylinder 1200 kg 1200 kg 1450 kg up to/fino a 10000 kg up to/fino a 10000 kg up to/fino a10000kg up to/fino a 10000kg

CLAMPING STROKE - Corsa chiusura stampo 50 mm 150 mm 150 mm 150 mm 150 mm 200 mm 150 mm 150 mm 150 mm 150 mm 150 mmCONTROL INTERFACE - Sistema di controllo PLC PLC PLC PLC PLC PLC PLC PLC PLC PLC PLC PLCOPERATE INTERFACE - Interfaccia operatore Display Display Display Display touch screen touch screen touch screen touch screen touch screen touch screen touch screen touch screenMAX MOULD SPACE LxWxH - Massima dimensione stampo 80X60X40 180X100X150 180X100X150 180X100X150 180X100X150 300x150x150 300x150x150 300x150x150 300x150x150 300x150x150 300x150x150

NUMBER OF MOULD - Nr. di stampi e supporto 1 1 1 2 1

1,5-slitta traslante-

sliding carrier 1 2 1 2 1 2

EJECTOR - Espulsore x x x x x x x x x

COMPARISON CHART/TABELLA COMPARATIVA

Documents

Web site: · Suitable Mold Project and Realization ... Single injection gun directly connected to gear pump ... Injection Type: