A resin casting system is a technical installation to process casting resin for the purpose of filling, sealing, covering or soaking technical parts, especially in the field of electricity and electronics like transformers, LCDs and other small and big parts.
Due to progressing miniaturization and introduction of electronics into new areas, quality requirements for the parts are rising, and thus the quality of casting must be increased as well. To obtain the required quality, on one hand, the resin system has to be developed and optimized accordingly. On the other hand, the resin casting system has to work more and more precisely to obtain best casting. Because of continuously increasing cost pressure, casting devices must be capable of increased quality, while also becoming faster and more reliable.
Requirements for good casting
First of all, by casting, electrical and electronic parts have to be insulated reliably and penetration of moisture has to be excluded totally. Very often heat has to be conducted out from the part properly, an attribute that can be improved by the choice of an appropriate casting resin.
Process steps in a resin casting system
In a resin casting system the following processes have to be performed:
Conditioning of the resin mix
Material transportation
Metering
Mixing
Dispensing
A good resin casting system provides high quality casting of the same high standard even during long series in mass production.
Conditioning
Several properties of the resin mix, with or without filler material, one component or two components (resin + hardener), are crucial for the quality of the product:
Even distribution of the fillers (no settling)
Elimination of air and moisture
Constant, often elevated temperature to maintain low viscosity
Even distribution of the fillers without setting is maintained by ongoing stirring.
Air and moisture are eliminated by evacuating the device.
Elevated temperature is reached and maintained by thoroughly controlled heating of the vessel, the material feeding lines, the pumps and metering heads. In filled, complex resin mixes conditioning is especially crucial for the quality of the product.
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