Product Details Supplier Info More products

Perpetuum is using low-pressure, low-temperature overmoulding with the Macromelt service from Engineering Solution and Henkel to protect components used on its vibration energy harvesting systems from the harsh operating environments in which they are used.

The Macromelt process has replaced traditional potting techniques, which the Southampton-based company had found prohibitively laborious.

Operating in environments such as oil-rig platforms, Perpetuum’s energy harvesters can be exposed to temperatures ranging from -40°C to +85°C, while for certain rail applications acceleration force can be anywhere up to 300G.

Both the coil and the PCB within the product need to exhibit mechanical strength and insulation resistance, meaning encapsulation was a key requirement.

Engineering Solution, through its partnership with Henkel, provides Macromelt — a low-pressure moulding service that sits in a class between casting and injection moulding.

Faced with producing an overmould for Perpetuum’s coil and PCB, measuring 48mm in diameter and 25mm in height, Engineering Solution created a one-part, single-hit mould tool capable of encapsulating the parts in a cycle time of around 60 seconds.

Key benefits of product application

  • Macromelt moulding is non-aggressive, cost-effective and fast.
  • Because it uses low pressures of typically 2–20 bar, lower-cost mould tools can be employed.
  • The technology is particularly suitable for encapsulating and enclosing delicate components and assemblies.
  • Perpetuum is now producing its second-generation vibration energy harvesting systems and the reliability of the Macromelt process is already assured, as confirmed by recently completed accelerated life tests.
  • The company is currently in discussions with Engineering Solution about the production of a multi-impression mould tool to make its requirements even more economic.

Henkel is the world market leader in state-of-the-art industrial adhesives, sealants and surface treatment products for a wide variety of engineering applications. Its leading brands for the industrial market are Loctite, Bonderite, Teroson, Aquence and Technomelt.

Strong customer focus, research and innovation, consistent quality and sustainable business practices have contributed to its record of success, as has continuous improvement in both its products and methods of manufacture.

The company applies its expertise to the entire value chain across the engineering sector. Whatever you build, manufacture, assemble or repair, its technical consultancy service will provide all the assistance and training you need to ensure you have the best product and the skill to apply to its best advantage.

Henkel brands are internationally renowned for their proven reliability and performance and the scope of the company’s product programme extends from cleaning and pre-treatment through to bonding, sealing, filling and protecting, coating and lubricating. 

Henkel is the only adhesive manufacturer to offer a comprehensive range of products that are hazard-label free. Its Loctite Health and Safety series is suitable for the lion’s share of engineering applications and includes thread lockers, thread sealants, gasketing adhesives, retaining compounds and instant adhesives.

As both the product and its method of application dictate the quality of process, Henkel also has considerable expertise in the supply of dedicated dispensing equipment that, if necessary, can be bespoke to the application. This equipment ensures the product is applied quickly, cleanly, accurately and economically.

View full profile