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Jetting With ExtremeJetting With Extreme

Precision

2 | DELO-News

Contents

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Microdispensing ValveThe New Dimensions of Jetting

Bringing Light Into the DarkLight Curing Even for Black Adhesives

Properly PackagedDELO Optimizes Packaging With a Focus on Sustainability

VorticesComponents Heated by Induction Within Seconds

(© D

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DELO-News | 3

Editorial

10

ImprintDELO Industrial Adhesives, DELO-Allee 1, 86949 Windach, Germany Phone +49 8193 9900-0, marcom@DELO.de, www.DELO-adhesives.com/en

Do you want to receive DELO News regularly?Then subscribe here: www.DELO-adhesives.com/en/newsletter

18

Dear readers,

Did you immediately recognize the cover picture as a pattern of tiny adhesive drops? How would you estimate their sizes? I’m going to tell you: One drop has a diameter of 300 µm.

“Smaller and faster” is the motto for advanced technologies, which include innovative dispensing solutions. Therefore, our pneumatic jet valve not only comes with improved handling properties, but also features increased jet performance. It now allows more types of adhesives to be jetted permanently and reproducibly in homeopathic quantities of a few micrograms.

Sabine Herold, Managing Partner

Pure EstheticsAdhesives in Crystal Houses Amsterdam

Fast SpeedstersDELO Supports Racing Teams

4 | DELO-News

Title story

Processing of diverse media

Media-resistant, high-performance elastomer seal

Easy-to-clean surface, no open electric contacts

Removable heating plate

Metal luer-lock adapter

Fluid box made of stainless steel

Robust and resistant to chemical attack; variably positionable media supply

Title story

DELO-News | 5

Integrated heater

Adjustable stroke

Flexibility through variable drop sizes

Typical service life > 1 billion cycles(patent pending)

Innovative pneumatic actuator

Actuator separated from fl uid box

Variable mounting options

Dispensing piston

Compressed air connection

Flexible, Fast and Robust:Flexible, Fast and Robust:DELO-DOT PN3Microdispensing valves are equipped with either pneumatic or

piezoelectric actuators, the last ones being less resistant to interference effects and shocks due to the combination of high

speeds and materials susceptible to breaking. Although actuators of pneumatic versions have a longer service life, they are usually provided with sliding sealing elements that are subject to abrasion and therefore limit the actuator’s service life in connection with high impact forces.

For the new DELO-DOT PN3 jet valve, DELO relies on a pneumatically driven actuator working entirely without any sliding or abrasive components. This leads to an extraordinary service life of more than one billion cycles, which, added to the high media resistance of the fl uid box ensures excellent productivity.

Title story

6 | DELO-News

High-throughput operation

More and more companies are opting for the jetting of adhesives in order to achieve high production throughput. With a maximum dispensing frequency of 330 Hz, the DELO-DOT PN3 is perfectly suited for this purpose. Mounted on a movable axis, its low weight of less than 350 g is ideal for high travel speeds and allows maximum dynamic performance.

The DELO-DOT PN3 valve is suitable for media of different viscosity, ranging from aqueous to pasty. The heater can be fi xed directly to the valve outlet and enables permanently stable temperature and viscosity conditions for the dispensing medium. Thanks to the built-in thermal insulation, only the medium-transporting part at the valve outlet is heated, thus reducing the time during which sensitive dispensing media are exposed to a defi ned thermal load.

Installation and maintenance made easy

During the development of this product, particular importance was also attached to easy integrability and maintenance in order to ensure faster and longer availability of the valve for its dispensing task. Especially in high-throughput systems, components need to be designed as compact as possible. The compact dimensions of the jetter (20.5 mm × 153 mm × 62 mm) in combination with a media supply that can be positioned at a 90-degree angle enable fl exible adaptation to small installation spaces and easy integration into production systems.

Despite the microdispensing system’s robustness, its medium-transporting components require regular cleaning and maintenance. This is where the benefi ts of the valve’s modular design and the separation of actuators and fl uid box become obvious. Cleaning is made easy, since all parts in contact with adhesives are accessible on all sides. The fl uid box can be replaced as a whole if necessary; single components such as the fl uid box body, nozzles of different diameters and geometries and the nozzle heater are available separately and can quickly be exchanged by the user.

Title story

DELO-News | 7

He tells you where the DELO-DOT PN3 excels in particular.

How is it possible to implement the process of dispensing such different quantities?

This is made possible by the optimized geometry of the fl uid box and two different piston types, one for very small dispensing amounts and one for small to medium drop sizes. The fl uid box is made of stainless steel, which makes it more robust and more resistant to chemical attack than its predecessor. The connected luer-lock adapter, as well, is no longer made of PEEK but of metal.

And what has changed in terms of handling?

It is now possible to set the stroke of the piston without any additional tool, just by means of a rotary wheel used to select one of fi ve different locking positions. The respective position is indicated by an LED, thus making it easier to check the stroke setting, in particular after integration into a production system. Furthermore, the newly developed nozzle heater has no open contacts and is simply clipped onto the valve, which facilitates disassembly for cleaning and maintenance.

What made DELO decide to enhance the previous microdispensing valve?

As an innovative company, we are always committed to continuous development and to pushing things forward. There is no standstill at DELO. Existing products are therefore constantly reviewed and improved where possible. The robust DELO-DOT PN3 valve has been developed with a special focus on performance and handling. We did not only concentrate on achieving optimal dispensing performance and reliability, but also wanted the valve to be easily managed by the customer. For, after all, what use is a good jet valve if it fails or is complicated to operate?

What is better about the brand-new jet valve from DELO?

The answer is quite clear: It’s its jet performance, which is signifi cantly increased as compared to the predecessor model. The valve is not only suitable for jetting many different adhesive types, but also in much smaller quantities. On average, the minimum dispensing amount is reduced by a factor three, and some media can even be jetted permanently in amounts as low as 0.009 mg. This is obviously an important point for our customers, given the increasingly smaller component sizes. But there is another benefi cial aspect of the DELO-DOT PN3: With a maximum dispensing volume of almost 14 mg, the valve covers a large fi eld of applications.

Interview with:Interview with:Robert Saller(International Sales Manager)

8 | DELO-News

Product

DELO Brings Light to the Dark SideLight-humidity curing, even for black adhesives

DELO has introduced black adhesives that are light-curable. These products are in demand for visual or safety reasons in many applications, but are very diffi cult to develop.

For light-curing processes, adhesive needs to be translucent so that photoinitiators in the entire adhesive layer can decompose and start the

crosslinking reaction. Because black absorbs the majority of light, the amount that is transmitted becomes naturally lower as the layer gets thicker.

However, the black dyed DELO DUALBOND GE4949 acrylate can be used for thicknesses of up to 500 µm. In addition to its light-curing component, it also contains a humidity-curing portion, which triggers crosslinking even in shadowed areas.

The acrylate is medium-viscous, has very good tension-equalizing characteristics thanks to a high elongation at tear, and achieves high strength on various plastics. It is particularly suitable for sealing and bonding of black components. This includes sealing wires, covering lettering, bonding clips or emblems, as well as sealing connecting terminals.

Also available for other adhesive chemicals

For the fi rst time, DELO has also dyed light-activated epoxy resins black that even can be light-cured at thicknesses of up to 1 mm. Unexposed areas are cured in a subsequent heat curing step. Possible applications for this include covering components for copy protection reasons or shielding against scattered light.

“Many customers request black adhesives that can be cured within seconds”, said Robert Saller, Director Sales International and Management Board Member. “That wasn’t very easy, but we can now demonstrate some good results with light here. In the future, we will continue expanding our product range, particularly in the fi eld of black, light-curing epoxy resins.”

Black Adhesives

are in demand, but diffi cult to develop

Product

DELO-News | 9

Temperature-stable, Allows for Flexible CuringNew 2C adhesive for e-motors from DELO

DELO has developed a new epoxy resin. The DELO-DUOPOX SJ8665 two-component product provides flexibility and reliability in the production of electric motors in a medium temperature range.

The adhesive features increased strength for this area of application. With 16 MPa on aluminum at a temperature of +80 °C, for example, it offers

double tensile shear strength compared to standard 2C epoxy resins. In addition, its temperature stability allows for low aging rates. Bond strength remains the same, even after 1,000 hours being stored at +85 °C with 85 % humidity.

This tough-hard adhesive of medium viscosity is particularly well suited for surface magnets which are subjected to sudden loads. Furthermore, it can be used for buried magnets and for fi xing the stator to the housing.

Fast and flexible production possible

Even though 2C epoxy resins cure at room temperature, it is possible to accelerate this process by heat. In the case of the new epoxy resin, it easily cures at varying times and temperatures, helping make the production process as fast and fl exible as possible. Functional strength is achieved within fi ve minutes, with full curing within 10 minutes, both at +80 °C. When induction cured at +100 °C, DELO-DUOPOX SJ8665 reaches a strength of 10 MPa within one minute. With fi nal curing of the adhesive done at room temperature, this makes it possible to directly continue the production process.

In contrast to one-component products, which need higher curing temperatures, DELO-DUOPOX SJ8665 is also used when bonding temperature-sensitive materials like plastics and magnetized metals. Furthermore, less time is needed to heat components which allows for faster assembly and a lower demand on energy.

DELO-DUOPOX SJ8665 is suitable for bonding of magnets, for example

User report

Standing out: The glass façade of the Chanel store(All photos on this page: © Daria Scagliola & Stijn Brakkee)

Looks like an ice palace:Even the window frames are made of glass

User report

DELO-News | 11

Stylish BONDING

DELO adhesive in Crystal Houses’ glass façade

With the new Chanel glass fl agship store, Amsterdam gained a new architectural highlight. Because the old brickwork has been replaced by glass blocks. DELOʼs products, more precisely the adhesive, is used for

bonding the more than 7,000 handmade glass elements of the façade. Thanks to the special properties of the PHOTOBOND adhesives, the bonding stays permanently transparent.

Video about the project https://youtu.be/WFleSzODnBM

With the Crystal Houses Amsterdam, the architects of MVRDV have created something unique. The complete façade of the old brick house has been

removed and replaced by new, transparent glass blocks. The frame of door and windows are also completely made out of glass elements.

Design plays a major role, particularly in the luxury goods sector. The architects have really succeeded in letting the façade of Crystal Houses stand out of the other shop façades in the street. The glass façade is an eye-catcher and lights brightly, especially in the dark.

DELO PHOTOBOND adhesives have been used in order to join the glass blocks reliably together. These adhesives are

characterized by their great elasticity and are tension-equalizing. This characteristic is a particularly important one, especially in a façade that is exposed to atmospheric infl uences like rainfall and heat. Moreover, the adhesives do not yellow even after years, but remain transparent, which is of utmost importance when bonding decorative elements like perfume bottles. The reliable adhesives made it therefore possible to do completely without traditional mortar.

Compared to conventional building adhesives that mostly cure at room temperature, DELO PHOTOBOND reaches its full strength thanks to UV light. The extensive bonding of the glass elements have been cured by the DELOLUX 20 / 400 fl ood lamps produced by DELO.

Trend

12 | DELO-News

Better to it !The new DIN 2304 standard for adhesive bonding technology assigns responsibility to users

The standard provides four steps to create structured bonding processes in the companies.

1. In the fi elds of design, planning, manufacturing, and maintenance, the companies employ professionally trained staff for adhesive bonding supervision.

2. Professional bonding requires availability of appropriate workplaces and manufacturing facilities meeting the requirements in terms of technology, work safety, and environmental protection.

3. With the assistance of the adhesive bonding supervisors, the design engineer or the person responsible for the component evaluates the bonded joint in consideration of the potential effects of its failure. This is done by categorizing it into safety classes, ranging from S1 (high) to S4 (none).

4. Both parties have to proof that the bonded joint meets the requirements throughout the life cycles and the intended period of use and that the bonding strength is greater than expected the expected stress.

Modern industrial adhesives are high-tech products that, if properly used, can ensure smooth production processes. If a bond fails during later use, this is

usually due to errors made in the customer’s production process. According to experts, about 90 percent of the errors occurring are based on insuffi cient knowledge of bonding.

This issue is addressed in the new DIN 2304 standard “Adhesive bonding technology – Quality requirements for adhesive bonding processes“, applicable since spring 2016. It defi nes rules for quality assurance in both technical and organizational terms, thus structuring the process of bonding in industrial use. This “detour” on the way to quality assurance is required for special processes such as bonding, since the quality of a bond cannot be inspected by non-destructive testing.

The DIN 2304 standard defi nes the state of the art for proper adhesive bonding of structural / load-bearing joints, applicable across all industries and products, to all adhesive classes and material combinations. It applies to all stages of the production chain, from development to manufacturing to maintenance.

DIN 2304 is the fi rst generally accepted standard for quality requirements in adhesive bonding technology. So far, only specifi c standards such as DIN 6701 for adhesive bonding in rail vehicle construction, have been used. This internationally accepted standard has been in force for ten years and is currently being converted into an EN standard, which might as well happen to the new DIN 2304 standard for adhesive bonding technology.

That is what

the standard

says

Trend

DELO-News | 13

What benefits do you see in this development?

Gudrun Weigel, Engineering Director and Member of the Executive Board: The new standard takes into account the complexity of adhesive bonding and creates the basis for professional and safety-related execution of bonding tasks. The users of adhesives get precise and clearly expressed instructions on organizational actions to take in preparation of bonding processes, allowing them to produce high-quality adhesive bonds that are highly reliable in use.

Do you see any disadvantages in the new DIN 2304 standard?

Weigel: First of all, it means increased bureaucracy. This, however, applies to organizational measures and documentation needed to ensure reliable manufacturing processes. Users are requested to review their processes, to invest in staff training and development, and to prove and document that the design complies with the strength requirements. But these are constructive measures to ensure effi cient bonding, which, in the medium term, will help save costs.

Do you support your customers in implementing the standard?

Weigel: The organization of processes needs, of course, to be implemented by the customers themselves. But we do expect more requests for advice and assistance regarding the selection of adhesives and materials, the constructive design, the discussion of suitable steps for effi cient production, and for information on reproducible production processes. These issues, however, have always been part of our customer services. And we provide additional assistance by offering training courses to their technical staff at our DELO Academy.

The standard is not a law and therefore not legally binding. However, if any issues concerning the reliability

of an assembly require legal clarifi cation, the user may probably be confronted at court with the question

of why the assembly does not meet state-of-the-art requirements or why the standard was not complied

with. Seen from a different perspective, companies adhering to the standard can also be discharged by providing documentation and proof of compliance.

That is what DELO says

Is the standard

mandatory?

14 | DELO-News

Tips & Tricks

The Catalyst Among the Heat Curing MethodsComponents heated by induction within seconds

Full curing of adhesives requires either patience or suitable tools to accelerate this process. Conventional 2C adhesives take between 24 hours

and up to seven days to reach their fi nal strength. In a manufacturing process, however, the curing time of adhesives needs to be adjusted to the cycle times in series production, which implies fast and highly reliable curing. To be clear: ideally, the adhesive should cure within seconds. Along with rapid curing using light, which is only possible for translucent components, thermally accelerated adhesive curing is a suitable method. This is usually done by supplying heat via ovens, but this method is too slow given the typical cycle times of 15 to 60 minutes. Furthermore, it does not provide location-specifi c or material-specifi c heating. Induction curing has great potential regarding rapid thermal curing and is an effi cient solution for metallic components.

What happens during induction curing?

During inductive heating, the metallic component is exposed, either partially or completely, to an alternating electromagnetic fi eld created by a current-carrying coil. This fi eld generates eddy currents within the material, fl owing

opposite of the original current and heating the material. Induction provides very fast heating of electrically conductive components and signifi cantly reduces the heat-up time, thus accelerating the curing process of heat-curing adhesives. Heating can be even more accelerated in the case of ferromagnetic substrates.

How is heat produced in the adhesive?

The surfaces of conductive metal components heat up very quickly by induction and transfer the heat to the adhesive. In the case of non-conductive workpieces such as ceramics or plastics, suitable additives like metal powder, for example, are added to the adhesives. This causes direct heating of the adhesive layer and consequently allows it to cure faster. In contrast to conventional heating processes, heat is generated directly in the adhesive which then cures within a few minutes or even seconds. Unlike with heat curing methods like radiation or convection, induction curing generates the heat in the conductive workpiece itself. Since the heat-up time is reduced with induction while the temperature remains the same as during oven curing, the adhesive molecules are smaller and more mobile, which accelerates crosslinking.

Tips & Tricks

DELO-News | 15

Advantages and disadvantages of induction

A clear advantage of induction heating over other methods is that induction allows targeted heating and curing of workpiece areas. Furthermore, cycle times are drastically reduced thanks to the rapid heating. The operation can be monitored by a specifi c process control system. The technical and economic benefi ts of induction are particularly evident with respect to energy effi ciency since heat losses are reduced. Therefore, to sum up, induction curing allows short cycle times, direct integration into production lines, reproducibility, process accuracy, and less energy consumption.

Conclusion Induction curing is an interesting option when reduced curing times and targeted heating of adhesives are required. Another important aspect is the energy-saving potential thanks to heating within seconds. Depending on the application in question, the inductive heating process needs to be tested with respect to the adhesive’s behavior, to frequency, and power and then optimized by an adequate temperature control.

Induction curing with camera for

quality control

Induction heating is limited by the penetration depth. Conductive heating is required for solid components where large interior areas have to be reached. Heat conduction takes longer than direct inductive heating. In addition, components should be more or less symmetrical to ensure homogeneous heating and the distance between the inductor and the component should be the same from any point. Complex geometries pose problems due to varying distances between coil and component, since the electromagnetic fi eld attenuates with increasing distance.

16 | DELO-News

Sustainability

An optimized box and insert design

makes it possible to accommodate 104 instead

of 60 cartridges on one Euro pallet.

It All Depends on the Right PackagingChristian Walther, Head of Production and Logistics, reports

We have long gone our own way in terms of optimized and sustainable packaging and shipping of adhesives. Thanks to our packaging and logistics concept, which is being constantly revised, we were

awarded second place in the Responsible Care Competition held by the German Chemical Industry Association (VCI).

As a specialist manufacturer of adhesives, we mainly develop products for applications, where only small amounts of adhesive are needed, yet have to meet stringent requirements. Because so little is needed in these applications, adhesives are generally fi lled in small plastic containers, like cartridges that have graduated capacities ranging from 5 ml to 1 l. Hobbocks are used for quantities of up to 30 l.

Several employees from different departments, including logistics, product management, customer quality support, engineering, and internal sales are in charge of the logistics concept. The team meets regularly to discuss how to improve delivery sustainability and effi ciency. Since adhesives are in fact chemicals that require safe transportation, the group focuses on the importance of maintaining a high level of safety as well. Sustainable logistics can only be achieved by many little steps of continuous improvement in terms of environment and safety.

There is some space left

One major improvement is the new packaging design with optimized cardboard box sizes. An example of such an adjustment is the packaging for the frequently

DELO-News | 17

Sustainability

used 20 oz (600 g) cartridges. For some time now, only 13 of these cartridges have been packed into a cardboard box, instead of 30 cartridges, as was customary in the past. This has reduced the weight from 18 – 24 kg to 8 – 12 kg and led to improved workplace safety. The layouts of the inserts for containers have also been optimized, making enough space for 30 % more cartridges.

The cardboard boxes now even make better use of an Euro pallet’s surface area, thus further reducing transport volume and storage space. Instead of 60 cartridges, there is now space for 104 cartridges on one layer.

As is standard practice, empty spaces in packaging boxes for adhesives need to be fi lled with cushioning material. We will reuse clean packaging material as much as possible. The bubble wrap used is recyclable and infl ated at our plant, which allows saving transportation and storage space.

Some attempts were made to replace Styrofoam chips with cornstarch-based, biodegradable products. However, once fl attened, the chips tested by us remained fl at and left lint residues. They also stuck to the containers when they came in contact with moisture. These aspects made us refrain from using chips made from natural ingredients.

Given the importance of transport safety in sustainable logistics, DELO has been using cardboard edge protection products for goods transported on pallets. The edge protection prevents palletized goods from being damaged by the retaining straps. This shows that even small steps are important in terms of environment and safety.

The journey is the destination

Set up as a bottom-up approach and following a concept of continuous improvement, the logistics team is continuously developing new and more sustainable shipping processes. Such projects generally focus on long-term achievements, since results cannot be measured until later in the process. What counts is that every step, as small as it may seem, contributes to future progress.

ess.o futur

Sponsoring

18 | DELO-News

DELO Supports “Speedy” University Projects

The World’s Most Economic

Electric Car

In July, the TUfast Eco Team set a new world record for vehicle effi ciency, earning them an entry in the Guinness Book of Records as the “Most effi cient electric vehicle”. Over a distance of 25 kilometers on an Audi test track, the car used up just 78.79 kilojoules. This is equivalent to 1,232.2 km / kWh or 11,000 km per liter of gasoline. To achieve the world record, the young designers had been working on their vehicle for more than one year. They managed to reduce its overall weight to around 20 kg and also optimized its aerodynamic properties.

DELO is sponsoring the racing teams TUfast Eco and TUfast Racing of the Technical University of Munich, the DHBW Engineering Team of Stuttgart, and the Starkstrom Team of Augsburg University. Lightweight construction and fast vehicles made possible through adhesive bonding.

The university teams used the provided adhesives for various bonding applications on their racing cars. This was mainly done on parts made of carbon, one

of the materials that allow constructing lightweight and

effi cient vehicles. Besides, all students received a training on bonding as part of a visit.

The members of the TUfast Eco Team, in particular, learned in a pleasant way that lightweight construction and a focus on sustainability pay off. Their purely battery-powered racing car was fi rst in its category at Shell’s Eco-marathon. With a weight of only 26.5 kg, their vehicle was the lightest one, reaching 863 km / kWh. Sustainable can also mean beautiful: The racing car, decorated with the futuristic name of “eLi15”, won the Design Award.

A lightweight of around 25 kg: the electric speedster “eLi15”

© TUfast e.V.

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