Joining technologies for sintered and plastic bonded magnets - ABM

Joining technologies for sintered and
plastic bonded magnets

Agenda
- Company presentation of MS-Schramberg
- Products
- Joining technologies for sintered and plastic bonded magnets
• Overmoulding with magnet compound
• Overmoulding with technical plastic
• Multi-component injection mould technology
• Gluing technology
• Ultrasonic Welding
• Other joining technologies

Our range of products:
• Hard ferrite magnets
• Rare earth magnets
• Plastic bonded
magnets
• Plastic and Plastic
Composite Parts
• Magnet assemblies
Company presentation:
MS-Schramberg Products

Company presentation:
Company development
1963
1973
1977
1985
1986
1992
1998
1999
2000
2001
2005
2006
2008-2009
2008
The „Tool and die construction“ department was expanded
The multi-component injection-mould technology was added for the
production line
Launch of production of magnet assemblies: Adhesive technology
Launch of production of rare earth magnets
Launch of production of plastic bonded magnets
Removing into new building in the industrial area of Schramberg-Sulgen
Renaming into „Magnetfabrik Schramberg GmbH & Co. KG“
Foundation of „Herbert Braun GmbH“; start of production of hard ferrite magnets
Construction of new plastics and
magnet assembly production plant
Renaming into
„MS-Schramberg GmbH & Co. KG“
Launch of production of micro-injection
moulded pieces;
Opening of representation office in Shanghai
Launch of production of technical plastic parts
Start of own „Automation technology“-department
The product line of magnet assemblies was expanded by
other joining technologies

Products:
Hard ferrite magnets
(barium-/strontium-ferrite)
Hard ferrite magnets have the
following advantages:
economical raw materials
very good resistance against
corrosion and chemicals
easy to magnetise

Applications:
(1) Linear sensor
(2) Permanentelectromagnetic
brakes
(3) Disc coupling
(4) Motive power
engineering
(5) Pumps
(6) Stepper motor
(7) Bicycle dynamo
(8) Separation magnets
(9) Magnet rollers
(10) Sensor technology
Products:
Hard ferrite magnets
(barium-/strontium-ferrite)
(3)
(1)
(2)
(9)
(4)
(5)
(8)
(10)
(7)
(6)

Products:
Rare earth magnets
(samarium cobalt/neodymium iron boron)
Rare earth magnets have the
following advantages:
high energy density
possibilities of miniaturization
low temperature coefficient
high magnetic stability

Applications:
(1) Medical technology
(2) - (6) Diverse engines
(7) Sensor technology
Products:
Rare earth magnets
(samarium cobalt/neodymium iron boron)
(1)
(7)
(5)
(6)
(2)
(3)
(4)

Applications:
(1) Sensor technology
(2) Clamping system
(3) Swing angle sensor
(4) Hysteresis brakes
(5) Motive power
engineering
(6) Position
identification
(7) Motive power
engineering
Products:
Plastic bonded magnets
(pressed magnets)
(2)
(1)
(3)
(6)
(7)
(2)
(4)
(5)

Applications:
(1) - (2) Rotational
speed measurement
(3) Angle measurement
(4) Flow measurement
(5) Yarn tension device
(6) Angle measurement
(7) - (8) Position
identification
(9) - (11) Rotational
speed measurement
Products:
Plastic bonded magnets
(injection moulded magnets)
(9)
(8)
(7)
(3)
(6)
(1)
(2)
(5)
(4)
(10)
(11)

Applications:
(1) Analog switch
(Automotive)
(2) Start-stopp-switch
(Automotive)
Products:
Plastic and Plastic Composite Parts
(Technical plastic parts)
(2)
(2)
(1)

Applications:
(1) small motors
(2) blood clamp
(medical
engineering)
(3) connectors
(4) drive wheel
(5) catches
(clock technology)
(6) optical lenses
Products:
Plastic and Plastic Composite Parts
(Micro injection mould parts)
(1)
(4)
(6)
(3)
(5)
(2)
(5)
(1)
(3)

Applications:
(1) Small motors
(2) Rotational speed
measurement
(3) Stepper motor
(4) Dynamo
(5) Fans
(6) Flow measurement
Joining technologies for sintered and plastic bonded magnets
Overmoulding with magnet compound
(4)
(1)
(6)
(2)
(5)
(3)
(2)
(5)

Joining technologies for sintered and palstic bonded magnets
Overmoulding with magnet compound
Design parameters:
- Shafts and bushings must have a positive fit (e.g. knurl)
- Magnet dimensions must be adjusted to bushings or shaft diameters
or wall thicknesses. Or in other words the magnet must be in the
right proportion with regard to its diameter, the bushing and the shaft
- The insert pieces must be high precision pieces in order to
minimize overinjections and in order to allow for an automised
production process

Applications:
(1) magnetic coupling
for gas meters
(2) magnetic coupling
for water meters
(3) pumps
(4) volume flow rate
measurement
(5) motor management
Joining technologies for sintered and plastic bonded magnets
Overmoulding with technical plastic
(3)
(5)
(4)
(2)
(1)

Applications:
(1) angle measurement
motor management
(2) steering angle
detection
(3) stepper motor
Joining technologies for sintered and plastic bonded magnets
Overmoulding with technical plastic
Gear systems to satisfy the highest demands:
(2)
(1)
(3)

Joining technologies for sintered and plastic bonded magnets
Example for an automised placement
process of insert pieces automation

Joining technologies for sintered and plastic bonded magnets
Multi-Component
Injection Moulding Technique for Plastic Bonded Magnets

Joining technologies for sintered and plastic bonded magnets
Multi-component injection mould technology
Overview: Two-component Injection Moulding
Technique
1.Internal movement within the mould
2.Transfer of the pre-moulded part into a second cavity:
2.1 Rotation of one mould half
2.2 Turning of an index plate/insert
2.3 Transfer from the first station into the second station
manually or using handling equipment

Joining technologies for sintered and plastic bonded magnets
Multi-component injection mould technology
1. Internal movement within the mould:

Joining technologies for sintered and plastic bonded magnets
Multi-component injection mould technology
1. Internal movement within the mould:
example

Joining technologies for sintered and plastic bonded magnets
Multi-component injection mould technology
Two-component Injection Moulding Technique:
Second moulding concept
2. Transfer of the pre-moulded part into a second cavity:
- Component 1 injected into the cavity
(= pre-moulded part).
- The pre-moulded part is transferred into another cavity.
Variation : 2.1 Rotation of one mould half
2.2 Turning of an index-plate/insert
2.3 Transfer from the first station into the
second station manually or using handling
equipment
- Component 2 injected.

Joining technologies for sintered and plastic bonded magnets
Multi-component injection mould technology
2.1 Rotation of one mould half:

Joining technologies for sintered and plastic bonded magnets
Multi-component injection mould technology
2.1 Rotation of one mould half:
example:
Rotor for speedometer drive gears
Ø 4,46 ±0,03 mm

Joining technologies for sintered and plastic bonded magnets
Multi-component injection mould technology
2.1.1 positive fit through additional raising and
lowering of plunchers:
Component 1 Component 2
1 Pluncher raised
1 2
2 Pluncher lowered (A riveted joint is made)
example:

Joining technologies for sintered and plastic bonded magnets
Multi-component injection mould technology
2.2 Turning of an index plate/insert:
1 – Component 1 injected
2 – Component 2 injected
3 – Rotation and index plate
3
1
2

Joining technologies for sintered and plastic bonded magnets
Multi-component injection mould technology
2.2 Turning of an index plate/insert:
example: Wheel of a radiator fan

Joining technologies for sintered and plastic bonded magnets
Multi-component injection mould technology
2.3 Transfer from the first station into the second
station manually or using handling equipment:
1 - Station 1
2 - Station 2
2
1
Concrete example:

Applications:
(1) Identification of
position
(2) Stepper motor
(3) Measurement of
turning speed
(4) Steering angle
detection
(5) Angle measurement
Motor management
Joining technologies for sintered and plastic bonded magnets
Multi-component injection mould technology
Samples:
(5)
(4)
(3)
(2)
(1)
(4)
(5)

Joining technologies for sintered and plastic bonded magnets
Multi-component injection mould technology
Advantages:
High level of precision
The ability to combine various performance characteristics in
one element
A vast range of possible designs (e.g. miniaturising)
A better quality of joints by fusion of various individual
components
Savings on materials
A reduction of the number of processing steps
The same processing conditions in every cycle
Elimination of expensive handling
The production of high quantities of complicated assemblies
at very reasonable prices

Joining technologies for sintered and plastic bonded magnets
Gluing Technology
Criterias for a good choice of a suitable glue:
Parts to
be joined
availability
Occupational &
environmental safety
costs
Suitable glue
Process
management
resistance
Quality
assurance
Stresses
and loads

Joining technologies for sintered and plastic bonded magnets
Gluing Technology
Joining Pieces
- Chemical properties of the surface e.g. contaminations
- Physical properties of the surface e.g. surface tension
- Mechanical properties: e.g. stability, rigidity
- Temperature resistance
- Resistances against physical and chemical stress
- Size and geometries of the gluing surfaces

Joining technologies for sintered and plastic bonded magnets
Gluing Technology
Occupational and Environmental Protection
- Possible glue substitutes with lower health risks
- Measures of protection
- Prevention of reject and recycling
- Legal regulations

Joining technologies for sintered and plastic bonded magnets
Gluing Technology
Process Management
- Process integration, cycle time
- Treatment of surfaces
- Required rheological studies (flow properties)
- Process parameters: time, temperature, pressure,…
- Fixation, hybrid joining
-Curing
- Tolerances

Joining technologies for sintered and plastic bonded magnets
Gluing Technology
Quality Assurance
- Incoming material inspection
- Storage conditions
- In line – inspections
- Inspection of components

Joining technologies for sintered and plastic bonded magnets
Gluing Technology
Loads and Stresses
- Mechanical and static stress, creeping
- Mechanical and cyclical stress, vibration
- Impact / shock
- Chemical stress: moisture, salt, grease, oil,…
- Physical stress: temperature, radiation

Joining technologies for sintered and plastic bonded magnets
Gluing Technology
Resistance against stress on a long term
basis
- Required life time of the bonding with regard to the
applied stress
- Considered test methods

Joining technologies for sintered and plastic bonded magnets
Gluing Technology
Types of glues being used with MS-Schramberg
- 1K epoxid resins
- 2K epoxid resins
- 2K PUR
- Cyanarcrylate
- anaerobic types of glue
- Methylmethacrylate
- Radiation curing glues

Applications:
(1) Linear position
identification
(2) Clamping system
(3) Linear motive power
(4) Rotational speed
measurement
(5) Linear position
identification
(6) Engine
(7) Clamping system
Joining technologies for sintered and plastic bonded magnets
Gluing Technology
Samples:
(7)
(1)
(2)
(3)
(6)
(5)
(4)

Joining technologies for sintered and plastic bonded magnets
Ultrasonic Welding
Materials which can be welded:
Amorphous and semi-crystalline thermoplastic plastic materials (e.g.
ABS, PA 6, PMMA, POM, PP, PS except PTFE)
Conditional TPE (thermoplastic elastomere) combine the properties
of cross-linked elastomeres with the advantage of a thermoplastic
processability
Steel
Copper
Aluminium

Joining technologies for sintered and plastic bonded magnets
Ultrasonic Welding
Overview on ultrasonic welding joining technology:
1. Seam welding
2. Spot welding
3. embedding 4. riveting 5. flanging

Joining technologies for sintered and plastic bonded magnets
Ultrasonic Welding
Seam Welding: Preferred design of seams
Stepped seam
Groove and tongue
seam
Pinched seam
Thin wall seam

Joining technologies for sintered and plastic bonded magnets
Ultrasonic Welding
Seam Welding:
Example for a thin wall seam
Example for a pinched seam

Joining technologies for sintered and plastic bonded magnets
Ultrasonic Welding
Spot Welding:
Moulding parts are butt-jointed tightly without creating a seam.
A specially shaped sonotrode pinpoint penetrates the upper
moulding part up until the middle of the lower moulding part while
the plastified material would be pressed firmly in a welding spot.
Part of the molten mass flows to the top and is then being
integrated annularly by the sonotrode.
Spot welding allows a homogeneous welding process of similar
and different thermoplastics (heterogeneous mixture/embedding).

Joining technologies for sintered and plastic bonded magnets
Ultrasonic Welding
Embedding:
Definition:
While the process of embedding the bore hole wall is being
plastified through the metal piece. The plastic flows into an
undercut in order to obtain a positive locking.
Options for embedding:
Threaded bushings
Metal grids (loud speaker)
Metallic screen tissue (shower head)

Joining technologies for sintered and plastic bonded magnets
Ultrasonic Welding
Riveting:
Riveting allows a positive locking of thermoplastics with different
materials, like metals, printed circuit boards, ...
Possibility of efficient multiple riveting at each welding stroke

Joining technologies for sintered and plastic bonded magnets
Ultrasonic Welding
Flanging:
Joining technology through positive locking – the insert piece is
being embedded into the plastic piece
Positive locking is achieved through a profiled sonotrode

Joining technologies for sintered and plastic bonded magnets
Other Joining Technologies
- Press-fitting
- Shrink wrapping
- Clipsing

Your requirements and wishes mean for us:
Chances
The realisation of your “dreams”
Challenge us!
Your partner for permanent magnets and plastic parts!
MS-Schramberg GmbH & Co. KG Telefon: +49 7422 519-0
Max-Planck-Straße 15 Telefax: +49 7422 519-1100
D-78713 Schramberg-Sulgen E-Mail: info@ms-schramberg.de
Internet: www.ms-schramberg.de
06/2008