Changes

Plastic molded or encapsulated Electromechanical components usually consist of stamped circuit patterns (lead frames), which are coated in the contacting areas with functional surface layers. They serve as the electrical connections of increasing importance due the component to rising requirements for smaller, lighter, and more compact designs the outside wiring. The lead frames are over-molded with cost efficient pricingplastics or mounted into plastic molded parts. Wherever mechanics and In addition, electronic meet, electromechanical components can be used in a multitude added to increase the level of applications, such as in automotive, communications, applianceproduct integration. Utilizing the metal–plastic compound, the mechanical stability of the plastic is combined with the conduction of electrical energy and consumer electronics engineeringelectronic signals through the lead frame.In automotive applications such components this way, protective enclosures for electronic controls of machinery are used in ever increasing volumescreated which at the same time serve as connecting points to the outside wiring. In This can be achieved through hybrid frames and housings electronic components are integrated into components for increasingly more complex engine management functions. StripOver-molded molding of contact components or assembly of different single parts are for example in plastic enclosures can also be used for seat adjustment, and airbag sensors; assembled contact parts are important functional to manufacture electromechanical components among others for memory mirror positioning units.

Electromechanical components usually consist of stamped circuit patterns (lead frames) which are coated in For achieving the contacting areas with functional surface layers. They serve as the electrical connections highest possible functionality of the component to the outside wiring. The lead frames are over-molded with plastics or mounted into plastic molded parts. In addition electronic components can be added to increase the level of end product integration. Utilizing , a close cooperation between the metal–plastic compound manufacturer and the mechanical stability of end user in the plastic is combined with the conduction early phases of electrical energy development and electronic signals through the lead frame. In this way protective enclosures for electronic controls design of machinery are created which at the same time serve as connecting points to the outside wiringnew custom tailored electromechanical components is recommended. This Innovative and cost-efficient designs can be achieved realized through hybrid frames and housings. Overthe combination of the know-molding how of the manufacturer in for example contact components or , coating, stamping, plastics processing, assembly of different single parts in plastic enclosures can also be used to manufacture electromechanical componentstechnologies and the mostly rather complex requirement profile given by the end user.

For achieving Besides the highest possible functionality of contact components, the end product a close cooperation between plastic materials are the manufacturer critical building blocks for electromechanical components. The Plastics used, are mostly technical thermoplastics and heavy-duty plastics which fulfill the end user in the early phases of development requirements for high mechanical strength, temperature stability and fatigue strength (<xr id="tab:Frequently Used Plastic Materials and design of new custom tailored electromechanical compotheir Properties"/><!-- nents is recommended(Table 10. Innovative and cost1)--efficient designs can be realized through >). For the combination final selection of a plastic material, economical considerations and the know-how avoidance of the manufacturer in environmentally hazardous ingredients, such as for example flame retardants, must be considered. The application of the most suitable contact, material coatingand the selection of carrier materials are covered in chapters [[Contact Carrier Materials|Contact Carrier Materials]], stamping, plastics processing, [[Surface Coating Technologies| Surface Coating Technologies]] and assembly technologies and the mostly rather complex requirement profile given by the end user[[Applications for Bonding Technologies|Applications for Bonding Technologies]].

Besides the contact components the plastic materials are the critical building blocks for electromechanical components<figtable id="tab:Frequently Used Plastic Materials and their Properties"><caption>'''<!--Table 10. 1:-->Frequently Used Plastic Materials and their Properties'''</caption> {| class="twocolortable" style="text-align: left; font-size: 12px"|-!rowspan="2" style="text-align:center;"| Type of Plastics used are mostly technical thermoplastics :<br />Poly-condensate<br />Sub-Type: Thermo-<br />plastics Abbrev.!colspan="6" style="text-align:center; padding:2px"| Properties|-  !Density<br />[g/cm³]!Reinforcement<br />Materials!mechanical!electrical!thermal!resistant against|-|'''PPS'''|1.34 - 1.64|glass fibers,<br />graphite fibers|very high mechanical strength and<br />stiffness even at high temperatures,<br />low toughness, very low creep,<br />better properties with addition of<br />40% glass fibers|excellent isolation<br />properties, very low<br />dielectric losses|usable up to 240°C, short term<br />up to 270°C, low combustibility,<br />self-extinguishing, non-dripping|up to 220°C no known solvents,<br />conc. sodium hydroxide,<br />conc. hydrochloric and heavysulfuric<br />acid, good hydrolysis resistance|-|'''PA6<br />PA66<br />PA610<br />PA11<br />PA12<br /> A amorph'''|1.12 - 1.14<br />1.13 -duty plastics which fulfill 1.14<br />1.06 - 1.08<br />1.04<br />1.01 - 1.02<br />1.06 - 1.12|glass fibers,<br />graphite fibers,<br />mineral powders,<br />glass beads, chalk,<br />lubricants such as<br />graphite, MoS₂|depending on the requirements for PA type, crystalline<br />structure and water content; high <br />mechanical strength, temperature stabilitystiffness, and <br />toughness; higher mech. strength<br />through stretching; very tough after<br />water absorption; high fatigue strength ,<br />good impact toughness, abrasion<br />resistant, good sliding properties<br />through addition of graphite and MoS₂;<br />increased mechanical strength with<br />glass and graphite fiber addition|depending on water<br />content, good surface<br />resistance reduces static<br />surface charge, high<br />dielectric losses, good<br />resistance against creep<br />currents|upper use temperature 80 – 120°C<br />depending on type, short term<br />up to 140 – 200°C, mostly<br />boil resistant, can be sterilized,<br />narrow softening range|aliphatic and aromatic<br />hydrocarbons, gasoline, oils,<br />greases, some alcohols, esters,<br />ketenes, ether,<br />many chlorinated hydrocarbons, <br />weak alkaline solutions|-|''(Table 10.1)'PBT'''|1. For the final selection of a plastic material economical considerations 29|glass fibers,<br />glass beads, minerals,<br />talcum |very high toughness at low<br />temperatures, good stiffness and the avoidance <br />mechanical strength, good long term<br />stability, low abrasion at good sliding<br />properties|good isolation properties,<br />good dielectric strength,<br />little effect of environmentally hazardous ingredients such as for example humidity|good thermal stability, use<br />temperature 60 – 110°C, short<br />term higher, with glass<br />reinforcement up to 200°C, low<br />tendency to turn yellow, very low<br />thermal expansion, burns with<br />sooty flame retardants must be consideredand drips|aliphatic and aromatic<br />hydrocarbons, fuels, oils, greases|-|'''LCP'''|1.40 - 1. The application of the most 92|glass fibers,<br />minerals |very high precision and dimensional<br />stability, high stiffness at low wall<br />thickness, low thermal expansion<br />coefficient; reinforced, better sliding<br />ability, electrically conductive and<br />suitable contact material for electroplating types|dielectric losses depend<br />on surface coating , good<br />electrical conductivity;<br />depending on type<br />suitable for anti-static<br />applications|use temperature 200 – 250°C,<br />good high temperature stability,<br />very low thermal expansion,<br />resistant to soldering<br />temperatures < 250°C, difficult to<br />combust and the selection of carrier materials are covered in chapters [[Contact Carrier Materialsself-extinguishing|good resistance against widely<br />used organic solvents, i.e.<br />acetone, methanol, chlorine gas,<br />acetic acid|-|'''PPA'''|1.26 - 1.85|Contact Carrier Materials]]glass fibers, [[Surface Coating Technologies<br />minerals | Surface Coating Technologies]] high impact strength with good<br />mechanical strength and [[Applications for Bonding Technologiesstiffness, very<br />high dimensional stability at high<br />temperatures, very low humidity<br />absorption|very low electrical losses|use temperature up to 185°C,<br />standard types with UL94-HB<br />classification, special flame<br />protective types|Applications for Bonding Technologies]]very good resistance against<br />typically used organic solvents, i.e.<br />acetone, methanol, etc., water<br />based solutions (DI water, 10%<br />ammonium hydride, typical liquids<br />used in the automobile such as<br />brake fluid, motor oil, etc|}</figtable>

Hybrid frames and housings serve as the connecting points between mechanics and electronics (<xr id="fig:Component with hybrid housing for use in automobiles"/> <!--(Fig. 10.1)-->). They allow the transmission of signals or electrical energy. The connection to the current paths inside the housing is mostly done by bonding with aluminum wires. The over-molded lead frames are typically manufactured from aluminum clad strip materials , which are well suited for bonding. The connectors integrated into the housing for transferring the current paths to the outside , are coated with tin, silver, or gold, depending on specific requirements.

[[File:Component with hybrid housing for use in automobiles.jpg|rightleft|thumb|Figure 1: Component with hybrid housing for use in automobiles]]

In strip form , over-molded contact parts reduce the complexity of assembly of the finished product. This complexity constantly increases with adding additional subcomponents (<xr id="fig:Examples of strip over molded contact components"/> <!--(Fig. 10.2)-->).

The strip over-molded contact parts can be tested for various quality parameters during manufacturing , to continuously ensure the ever increasing reliability requirements of the end components.

Combining stamping and molding techniques in an automated production line allows the stamped contact parts to be molded into plastics as a complete functional unit. This also allows enables to reduce manufacturing tolerances to levels below those achievable with conventional assembly methods.

[[File:Examples of strip over molded contact components.jpg|rightleft|thumb|Figure 2:Examples of strip over molded contact components]]

[[File:Examples of assembled contact components.jpg|rightleft|thumb|Figure 3: Examples of assembled contact components]]

Table 10.1[[de: Frequently Used Plastic Materials and their PropertiesKunststoff-Metall-Verbundteile]]