Electrical components in a single molding operation - Polymer experts at Siemens develop conductive plastic compound for processing in injection molding machines Photo Courtesy of Siemens

September 8, 2004 -- Erlangen, AG -- Jobwerx News -- Siemens has developed a composite made of plastic and metal that can be processed like a plastic, but has the electrical and electromagnetic properties of metal. Polymer experts at Siemens develop conductive plastic compound for processing in injection molding machines.

The new plastic-metal hybrid has the electrical and electromagnetic properties of metal and is designed to simplify the production of electrical components such as transmission and engine control units. When heated, the material can be processed with conventional injection molding machines as used in the plastics industry. Numerous experiments have shown that conductor paths as well as contacts for plug-in connections or cables can be injection-molded with the material in one operation. Time-consuming soldering processes are no longer necessary and the production process is speeded up.

Electronic engine components are usually enclosed in plastic housings which are formed from molten plastic in injection molding machines. In subsequent production steps automatic machines apply thin metal layers on the inside of the housing to act as conductors, and then solder resistors, electrical coils and plug-in connections permanently in position. Finally cables are screwed on. In other words a large number of production steps are necessary to make a finished control unit the size of a cigar box, for example for fuel injection valves. Developers at the Functional Polymers department of Siemens Corporate Technologies in Erlangen hope to speed up these processes with the new plastic-metal hybrid. The material consists of about 10 to 20 percent plastic, and about 50 percent copper. The rest is made up of a solder that melts at relatively low temperatures. In combination the various ingredients give the special plastic its unusual properties.

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