RAMPF Polymer Solutions GmbH & Co. KG Thilo Heuft / 05.11.2015 High performance reactive resins for component protection in extreme environments
The RAMPF Group RAMPF stands for Engineering and Chemical Solutions. RAMPF Machine Systems RAMPF Production Systems RAMPF Eco Solutions RAMPF Polymer Solutions RAMPF Tooling Solutions RAMPF thinks globally and acts locally. RAMPF Group Inc. Wixom, MI Suwannee, GA RAMPF (Taicang) Co., Ltd. Taicang, Jiangsu Province RAMPF Group Japan K.K. Osaka SERVICE WORLDWIDE. > 44 distribution partners www.rampf-gruppe.de 2
RAMPF Polymer Solutions Integrated Solutions RAMPF Polymer Solutions is specialist for reactive resin systems We offer a comprehensive product range: > Polyurethanes (foam and compact materials) > Epoxies (cold- and hot curing, 1C/2C) > Silicones (foam, compact materials, 1C/2C) Since more then 30 years RAMPF and our partners are offering outstanding technical solutions based on our innovative concept: www.rampf-gruppe.de 3
Strategies to protect components > Encapsulating of components: Resin is used for embedding and thus protecting form direct environmental influences > Sealing of enclosures: Component is contained in an enclosure that protects against external environmental conditions www.rampf-gruppe.de 4
Strategies to protect components > Encapsulating of components: Resin is used for embedding and thus protecting form direct environmental influences > Sealing of enclosures: Component is contained in an enclosure that protects against external environmental conditions www.rampf-gruppe.de 5
Encapsulation of components Overview of applications Electro Casting Resins Passive Components Sensors Transformers Motors Automotive electronics www.rampf-gruppe.de 6
Encapsulation of components Typical requirements > Protection against moisture, dust, shocks and overheating. > Temperature resistance. (RTI listed) > Thermal shock resistance. > Chemical resistance. > Thermal conductivity. > Mechanical strength. > Flame-retardant systems (UL 94 listed). > Dimensional stability. > Electrical insulation system. (OBJS2 listed) > Dielectric properties. > Low water absorption. > Hydrolytic resistance. > Adhesion to the housing. > Impregnation capability. www.rampf-gruppe.de 7
Encapsulationof components Fire Resistance The main standard is UL 94, an US standard of Underwriters Laboratories Inc. (UL) It allows to determinate plastic materials flammability (classification V0, V1 or V2) submitted to a defined temperature flame, on a upright position and during twice 10 seconds. (test on the lab) > UL 94: the standard > V0,V1,V2 is the classification (describes reaction to fire) > Thickness is a key parameter (V0 for 1mm, more difficult than V0 for 6mm) www.rampf-gruppe.de 8
Encapsulation of components Thermal Conductivity > Thermal conductivity describes the ability to transport thermal energy in the form of heat. > High thermal conductivity is important to > deflect electrical energy dissipation shown as heat > Avoid mechanical stress caused by thermal changes > Challenge for casting resins: > Unfilled resins show a low thermal conductivity (~0.2 0,3 W/m*K) are easy in processing > Filled resins have a higher thermal conductivity (~0,8-1 W /m*k) and still can be processed with standard process > Thermal conductivity of up to 2,5 W/m*K is possible but only with special formulation and process www.rampf-gruppe.de 9
Encapsulation of components Relative Temperature Index (RTI) > Target: to describe the thermal aging of materials under temperature influence for a long period of time. > Criterion: Testing at various temperatures the decrease of a physical characteristic (electrical or mechanical) to 50% of the initial value or at the latest after 10.000 hours > Results: Using the Arrhenius equation the findings are extrapolated to > 20.000 hours (TI as per IEC 216 or DIN EN 60216) > 100,000 hours (RTI as per UL 764 B) Old IEC 60085 IEC 60085: Thermal class Max. Working T in C A 105 E 120 B 130 F 155 H 180 www.rampf-gruppe.de 10
Encapsulation of components Mixing and dosing Usually low pressure dispensing systems using: > Piston or gear pumps. > Static or dynamic mixing heads. But not every kind of casting resin can be used with every kind of dispensing machine. Many parameters should be considered : > Viscosity of product > Reactivity > Mixing ratio > Out put rate > Content and type of filler Dynamic mixer static mixer Potting under vacuum is a reliable method to prevent voids or bubbles in the resin can lead to dielectric or mechanical failure. www.rampf-gruppe.de 11
Encapsulation of components Process parameters In order to define the best process, many parameters should be optimized and fixed: > Temperature of the products. > Output rate. > Casting point and number of shots. > Preconditioning of the parts. > Curing and post curing. www.rampf-gruppe.de 12
Encapsulation of components video examples www.rampf-gruppe.de 13
Strategies to protect components > Encapsulating of components: Resin is used for embedding and thus protecting form direct environmental influences > Sealing of enclosures: Component is contained in an enclosure that protects against external environmental conditions www.rampf-gruppe.de 14
Sealing of enclosures Current technologies FIPG/FIPFG Cellular PE Soft-sponge rubber Cellular rubber www.rampf-gruppe.de 15
Sealing of enclosures FIPFG Formed In Place Gasket compact foamed Formed In Place Foam Gasket Why this technology? > No leakage, since no joint connection as with conventional, bonded continuous gaskets > Process safety (automation) > Economic solution www.rampf-gruppe.de 16
Sealing of enclosures Typical Requirements Protection against dust and liquids (oil, water, ) Compensation of tolerances Needs for sealing systems NVH (Noise Vibration Harshness- absorption features) Adhesion to casing Low emission systems for Interior VDA 278/270 Low compression-set Fire resistance www.rampf-gruppe.de 17
Sealing of enclosures Compression Set Measurement principle > With a stamp the specimen is compressed to e.g. 50% of its original height > Compression is kept for e.g. 1 day 9 12 6 3 24 h > Relaxation after removing compression > Measurement of the remaining height 30 min. after load removal www.rampf-gruppe.de 18
Sealing of enclosures FIPFG technology with special features Anti-microbial gasket for clean-room luminairs Non-fogging foam for automotive door-module (GRP) Flame ressistant gasket for electrical cabinets (GRP / Metal) www.rampf-gruppe.de 19
Sealing of enclosures Machine concept Material Supply A Material Supply B Air loading regulator max. min. max. min. Material tank A Recirculation pump Material tank B Dispensing pump Dynamic mixing head www.rampf-gruppe.de 20
Sealing of enclosures Advantages of PUR foam gasket Low water absorption Good ageing resistance High mechanical & thermal performance No plasticiser Short curing process without oven Customized solutions for specific needs Cost effective solution Approval UL 50, UL 94, FDA, VDI 6022, DIBt www.rampf-gruppe.de 21
Sealing of enclosures Video example www.rampf-gruppe.de 22
RAMPF Group Worldwide SERVICE WORLDWIDE. RAMPF Group, Inc. Wixom, Michigan, USA E info@rampf-group.com www.rampf-group.com RAMPF (Taicang) Co., Ltd. Taicang, P.R. China E info@rampf-group.com.cn www.rampf-group.com.cn RAMPF Group Japan, K. K. Osaka, Japan E info@rampf-group.jp www.rampf-group.jp RAMPF Polymer Solutions GmbH & Co. KG Robert-Bosch-Str. 8-10 D-72661 Grafenberg T +49.71 23.93 42-0 F +49.71 23.93 42-2444 E polymer.solutions@rampf-gruppe.de www.rampf-gruppe.de