The encapsulation of ignition distributors requires special materials and a dispensing system with precision temperature controls and exact material metering.

The encapsulation of ignition distributors requires special materials and a dispensing system with precision temperature controls and exact material metering. Manufacturers of sensitive electronic components often use an encapsulating compound to guard against dust, moisture and vibration. This under-hood application involves the protection of an ignition module against environmental factors and the high voltage output of the ignition system.

As vehicles become dependant on computer chips and electronics, it become important to protect these components against the constant heat, moisture, oil, dirt, vibration and in this case - high voltage.

The requirements are very demanding: the encapsulating compound that fills the distributor modules must act as a high quality insulator protecting the electronics from continuous high voltage.

The material must not contain any air inclusions (bubbles).

Bubbles lead to sparking which destroys the printed circuit board in the distributor.

This encapsulating compound consists of two parts; one is filled with a glass fiber.

Kern-Liebers Dispensing Technology developed a solution for this very difficult application in cooperation with the automotive component supplier.

During system development, attention is focused on temperature monitoring since acceptable results can only be obtained when specified temperatures are stringently maintained.

System temperature is continuously monitored at twenty measuring points and corrected if necessary.

Both material reservoirs are temperature-controlled, one at 80 degrees, the other at 60 degrees Celsius preventing the formation of bubbles and allowing the material reach the required fluidity.

A vacuum system used in the reservoirs reduces the pressure to 3 millibars removing trapped air bubbles.

The parts are pre-heated to 60 degrees Celsius, ensuring the mixed material retains it fluidity during dispensing.

The material is fed to the mixing unit by a reliable and proven media transfer system.

This system and all transfer hoses are temperature-controlled, keeping the material flowing properly.

A material ratio of 1:1 is precisely mixed with Kern-Liebers metering pumps ensuring an accurately mixed final compound.

Curing takes place in two, five-meter continuous furnaces, the first at 80 degrees and the second at 120 degrees.

Overly high temperatures are also not permitted since the module electronics are temperature sensitive and can be ruined by excessively high temperatures.

The system controller has the temperature indicators along with pressure sensors for the material reservoirs.

The operator keeps all system data in sight because it is displayed on a monitor at the loading and unloading position.

Kern-Liebers is a manufacturer or precision dispensing equipment with corporate offices in Schramberg, Germany employing more than 2700 employees in 21 operating companies on all continents.