Materials for Automotive Electrical and Electronic Components

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S t a r t with DuPont Engineering Polymers Materials for automotive electrical and electro n i c c o m p o n e n t s DuPont Automotive Today automotive electronics are expanding at an unprecedented rate. Driven by advanced technology and governmental mandates, the electrical content of automobiles is expected to double by the year 2000. From air bags to anti-lock braking systems to more precise engine and emission controls, electronics are the key to improved e fficiencies, safety and convenience.

Electrical components must function over a broad range of temperatures while withstanding impact, vibration, and assorted corrosive fluids. To d a y 9s automotive engineer must choose a material that affords a durable and cost-effective part. We hope to simplify the selection process by pre- senting DuPont materials that are best suited for your evaluation in v a r i o u s electrical/electronic applications.

DuPont materials Z Y T E L ® nylon, R Y N I T E ® P E T a n d C R A S T I N ® P B T polyester products have become industry standard resins f o r use in bobbins, ignition coils, relays, connectors and sensor encapsulations. ... more. less.

These products have a proven track record in such applications due to their ability to withstand automotive fluids, temperature extremes and impact. In addition, DuPont has developed new materials such as Z Y T E L ® H T N (High Temperature Nylon) and Z E N I TE T M Liquid Crystal Polymers for extremely high temperature applications. To help you meet the unique challenges facing the automotive industry today, DuPont offers our full line of engineer- ing polymers, plus specialty products for insulation, bearings and wire and c a b l e . Worldwide capabilities With more than 200 plants and labo- ratories to serve the global automotive market and with thousands of people dedicated to automotive technology, DuPont can meet your needs world- w i d e . S t a rt with DuPont The information in this brochure is a general guide to materials in auto- motive electrical components. For a specific project, our application specialists will work closely with you to select the right material for evalua- tion in your application and will assist you in its proper design, testing and fabrication techniques. To discuss your specific needs, contact your local DuPont subsidiary at the addresses shown on the back page. S t a rt with Du Pont ® DuPont registered trademarks TM DuPont trademarks 1 P roblem-solving technology from DuPont. F l u o r o p o l y m e r s T E F L O N ® fluorocarbon resins T E F Z E L ® fluorocarbon resins V I T O N ® f l u o r o e l a s t o m e r Films for e l e c t r i c a l i n s u l a t i o n M Y L A R ® polyester film K A P T O N ® polyimide film Paper for e l e c t r i c a l i n s u l a t i o n N O M E X ® aramid paper Wire & Cable M a t e r i a l s A L C R Y N ® melt processible rubber E L V A L O Y ® P V C m o d i f i e r s H Y P A L O N ® synthetic rubber H Y T R E L ® e n g i n e e r i n g thermoplastic elastomer K A P T O N ® polyimide film N O R D E L ® hydrocarbon rubber T E F L O N ® fluorocarbon resins T E F Z E L ® fluoropolymer V A M A C ® e t h y l e n e / a c r y l i c e l a s t o m e r E n g i n e e r i n g p o l y m e r s A L C R Y N ® melt processible rubber C R A S T I N ® P B T polyester resins D E L R I N ® acetal homopolymers H Y T R E L ® e n g i n e e r i n g thermoplastic elastomer M I N L O N ® mineral reinforced n y l o n s R Y N I T E ® P E T polyester resins Z E N I T E T M liquid crystal polymers Z Y T E L ® 6 and 6.6 polyamide resins Z Y T E L / K E V L A R ® S F C short fibre c o m p o s i t e C o m p o s i t e s E s S E E ® a d v a n c e d c o m p o s i t e s Material for h i g h p e r f o r m a n c e b e a r i n g s V E S P E L ® S P p o l y i m i d e H i g h p e r f o r m a n c e parts and shapes for m o t o r c o m p o n e n t s and high t e m p e r a t u r e a p p l i c a t i o n s V E S P E L ® journal bearings V E S P E L ® thrust devices V E S P E L ® i n s u l a t o r s / i s o l a t o r s V E S P E L ® coil forms DuPont solutions for Auto E/E applications C o n n e c t o r s Dimensional stability, impact resistance, high flow mouldability and chemical and temperature resistance are important performance requirements. Grades of Z Y T E L ® nylon are most often selected along with grades of C R A S T I N ® P B T and R Y N I T E ® P E T polyesters, H Y T R E L ® engineering thermoplastic elastomer and Z E N I T E T M liquid crystal polymer. All these grades are also available in f l a m eretardant versions. Coil Bobbins S t i ffness, impact resistance and thin wall mouldability are important material selection criteria for coil bobbins. In addition, temperature resistance and electrical properties can determine the best material choice. Grades of R Y N I T E ® and C R A S T I N ® polyester and Z Y T E L ® nylon are specified for the vast majority of coil bobbins for automotive electrical c o m p o n e n t s . Electric Motors Electric motors used in automotive applications require engineering materials with high temperature properties, dimensional stability, low wear and friction, mouldability and chemical resistance. The main use of engineering plastics in automotive electric motors occurs in the drive (gear) housing. DuPont has expertise in warpage analysis and F E A to select materials such as R Y N I T E ® 545, C R A S T I N ® S K 6 0 9 , Z Y T E L ® 70G50 H S Lthat best balance the load requirements with mouldability and M I N L O N ® 1 3M Mto achieve low warpage. For gear trains DuPont off e r s D E L R I N ® acetal homopolymer which is used extensively for helical window lift gears. Other DuPont products such as V E S P E L ® polyimide offer low wear and low friction for bearings. 2 3 S e n s o r s/S o l e n o i d s Thermoplastic materials used to encapsulate/overmould sensors and solenoid coils must be resistant to a variety of automotive fluids such as engine oil, transmission fluid and road salts. They must also possess high flow characteristics to enable low pressure moulding and minimum distortion of fragile electrical components (fine w i r e ,Hall Effect chips, etc). DuPont has developed grades of Z Y T E L ® n y l o n , R Y N I T E ® and C R A S T I N ® p o l y e s t e r e s p e c i a l l yfor these applications, eg Z Y T E L ® F E5382 and C R A S T I N ® T 8 0 5. Ignition Coils Modern electronic ignition systems ( D I S ) demand materials that possess excellent dielectric properties and durability over a temperature range of -40 °C to +150 °C and voltages up to 40 kV. Adhesion to epoxy potting/ insulation compounds is also critical. D u P o n t 9s R Y N I T E ® P E T and C R A S T I N ® P B T polyester resins are used widely in such applications. For example, R Y N I T E ® 935 polyester is employed by several original equipment manu- facturers in ignition coil cases due to its outstanding dielectric performance and adhesion to epoxy compounds. For specific applications, hydrolyses resistant grades of P E T can also be d e v e l o p e d . S w i t c h e s Interior input control switches, such as multi function turn signal switches and master light control units, typically make extensive use of engineering thermoplastics. Materials off e r i n g good stiffness, impact resistance, low warpage and chemical resistance such as DuPont Z Y T E L ® , M I N L O N ® , C R A S T I N ® and D E L R I N ® meet both chemical resistance and higher temperature requirements. DuPont expertise in product design and warpage analysis can help you e fficiently design and manufacture switch assemblies that meet your performance goals. Our 8snap fit 9 and 8hinge 9 design software can help consolidate parts for your switches and cut down on design time. R e l a y s Relays function as electrically activ- ated switches. Temperature resistance, s t i ffness and thin wall mouldability are important material criteria, along with electrical properties such as diel e c t r i c strength as miniaturised compon e n t s are being designed. Grades of R Y N I T E ® P E T , C R A S T I N ® P B T a n d Z Y T E L ® nylon are broadly used for relay coil forms, bases and cases. 5 Unreinforced PA66 Unreinforced PBT, HB Highly nucleated PA66 30% Glass-reinforced PA66 13% Glass-reinforced PA66, toughened 30% Glass-reinforced PBT/ASA Unreinforced PA66, VO 25% Glass-reinforced PA66, VO 30% GR, PBT, VO 30% Glass-reinforced PBT/ASA, low warp, VO Thermoplastic elastomer, high modulus " Stiffness " Dimensional stability " Thermal cycling durability " UL system approvals " High viscosity " Toughness " Fast cycling " Stiffness " Heat resistance " Toughness " Low warp " Toughness " UL-VO at 0.5 mm " Stiffness " UL-VO at 0.5 mm " Stiffness " Temperature strength " UL-VO at 0.8 mm " Low warp " UL-VO at 1.6 mm " Hinge functionality " Sealing functionality " Impact resistance POM homopolymer, high strength 20% KEVLAR ® reinforced PA66, extremely low wear " Low friction " Stiffness " Strength " Low wear " Extremely low wear " Strength Impact modified Flame retardant Flame retardant High hinge functionality Z YTEL ® 101 L C RASTIN ® S600 Z YTEL ® EFE1151 Z YTEL ® 70G30 HSL Z YTEL ® 79G13 HSL C RASTIN ® LW9030 Z YTEL ® FR7200 VOF Z YTEL ® FR70G25 VO C RASTIN ® SK645 FR C RASTIN ® LW9030 FR H YTREL ® 8238 D ELRIN ® 100 Z YTEL ® 70K20 G E A R S C O N N E C T O R S TypicalProduct ComponentsRecommendedDescriptionKey benefits D uPont Polymers Automotive Electrical Components This chart lists several of DuPont Engineering Polymers r e c o m m e n d e dfor automotive electrical components. For additional information and specific application assessment, contact your local DuPont sales representative. 4 POM homopolymer, high molecular weight. Low wear and friction. 30% Glass-reinforced nylon 30% Glass-reinforced PET 30% Glass-reinforced PBT " Stiffness, strength " Low wear, low friction for moulded in functional components " Stiffness " Toughness " Heat resistance " Stiffness, strength " Temperature resistance for underhood environment " Dimensional stability " Stiffness " Temperature resistance " Dimensional stability 30% Glass-reinforced PET 55 % Glass-reinforced PET 30% Glass-reinforced PBT 30% Glass bead PBT isotropic 30% Glass-reinforced PA 66 30% Glass-reinforced PET, flame retardant 30% Glass-reinforced 25% Glass-reinforced PA 66, G25, VO " Stiffness " Dimensional stability " Thermal cycling durability " UL system approvals " Stiffness " Temperature strength " Dimensional stability " Stiffness " Temperature resistance " Dimensional stability " Isotropic properties " Low warpage " Stiffness " Toughness " Heat resistance " Stiffness " UL-VO at 0.35 mm " Stiffness " Toughness " UL-VO at 1.6 mm " Stiffness " UL-VO at 0.5 mm D ELRIN ® 100 Z YTEL ® 70G30 HSL R YNITE ® 530 C RASTIN ® SK605 Coil bobbins flame retardant R YNITE ® 530 R YNITE ® 555 C RASTIN ® SK605 C RASTIN ® SO655 Z YTEL ® 70G30 HSL R YNITE ® FR530 C RASTIN ® CE7931 Z YTEL ® FR70G25 VO C O I LB O B B I N S B R A C K E T S TypicalProduct ComponentsRecommendedDescriptionKey benefits ACTUATORS (see cHousings d) 30% Glass reinforced PBT, VO 25% Glass-reinforced PA66, VO 30% Glass reinforced PA66 15% Glass reinforced PET, flame retardant " Stiffness " Toughness " UL-VO at 1.6 mm " Stiffness " UL-VO at 0.5 mm " Stiffness " Stiffness " High flow " Flame retardancy 45% Glass-reinforced PET 50% Glass-reinforced PBT 30% Glass-reinforced PET, flame retardant 16% mineral reinforced PA66, toughened 45% Glass-reinforced PET 50% Glass-reinforced PA66 " High mechanical strength " Dimensional stability " Temperature resistance " Stiffness " Temperature resistance " Stiffness " Flame retardancy " Toughness " Surface finish " Stiffness " Temperature resistance " Stiffness " Temperature resistance 35% Glass/mica reinforced PET 35% Glass-reinforced PA66 20% Glass bead reinforced PBT " Low warpage " Stiffness " Dimensional stability " Stiffness " Low warp " Dimensional stability Fuse boxesR YNITE ® 935 Z Y T E L ® 70G35 HSL C RASTIN ® SO653 C RASTIN ® C E 7 9 3 1 Z Y T E L ® FR70G25 VO Z Y T E L ® 70G30 HSL R YNITE ® F R 5 1 5 R E L A Y S End shields Brush holders End caps Fans R YNITE ® 545 C RASTIN ® SK609 R YNITE ® FR530 M INLON ® 13MM R YNITE ® 545 Z Y T E L ® 70G50 HSL 7 TypicalProduct ComponentsRecommendedDescriptionKey benefits 15% Glass-reinforced PET, GW 960 °C 25% Glass-reinforced PA66 Melt processable rubber, 60 Shore A " High glow wire temperature " Stiffness " Temperature resistance " Mouldability " High production rate Lamp sockets Back caps Seals R YNITE ® RE9085 Z YTEL ® 70G25 HSL A LCRYN ® 2060 35% mineral/glass reinforced PET 36% Glass fibre/flake reinforced PET 40% mineral reinforced PA66, toughened 20% Glass-reinforced PBT/ASA, low warp, VO 30% Glass-reinforced PBT/ASA blend, low warp, VO " Low warpage " Adhesion to epoxy potting compounds " Stiffness " Stiffness " Temperature strength " Low warp " Dimensional stability " Toughness " Stiffness " Low warp " Flame retardancy " Stiffness " Low warp " Flame retardancy 55% Glass-reinforced PET 30% Glass-reinforced PBT/ASA blend 35% glass/mica reinforced PET 50% mineral/glass reinforced PBT high tracking resistance " High mechanical strength " Stiffness " Low warp " Low warpage " Adhesion to epoxy potting compounds " Excellent dielectric strength " Stiffness " High tracking resistance Actuator housings Mas Air Flow Sensor Housings Large Housings Low warp R YNITE ® 935 R YNITE ® RE5213 M INLON ® 11C140 C RASTIN ® LW9020 FR C RASTIN ® LW9030 FR Coil bobbins Coil cases and trays Distributor caps R YNITE ® 555 C RASTIN ® LW9030 R YNITE ® 935 C RASTIN ® HT1619 H O U S I N G S I G N I T I O N L I G H T I N G 6 TypicalProduct ComponentsRecommendedDescriptionKey benefits MOTORS / ALTERNATORS POWER DISTRIBUTION / BOXES 30% Glass reinforced PA66 PA66 Glass reinforced sensor resin 30% Glass reinforced PBT, high elongation 30% Glass reinforced PBT, VO, high elongation PA 6,12 / 33% Glass reinforced 15% Glass reinforced PET, toughened 30% Glass reinforced PET " High strength " Toughness " High flow " Strength " High elongation " Stiffness " High elongation " Flame retardancy " High flow " Low crystallisation rate " Thermal cycling durability " Easy moulding " Impact resistance " High flow " Excellent surface finish " Stiffness " High flow Unreinforced PA66 15% Glass-reinforced PA6 30% Glass-reinforced PA66 Amorphous nylon, transparent 15% Glass-reinforced PBT POM homopolymer, high mouldability " Stiffness " Toughness " Stiffness " Toughness " Temperature resistance " Stiffness " Toughness " Temperature resistance " Transparency " Chemical resistance " Stiffness " Temperature resistance " Low friction " Low wear " Strength Z YTEL ® 70G30 HSL Z YTEL ® FE5389 BK276 C RASTIN ® T805 C RASTIN ® T845 FR Z YTEL ® FE5382 R YNITE ® 415 HP R YNITE ® 530 Z YTEL ® 101 L Z YTEL ® 73G15 Z YTEL ® 70G30 HSL Z YTEL ® 330 C RASTIN ® SK602 D ELRIN ® 500P S W I T C H E S 8 TypicalProduct ComponentsRecommendedDescriptionKey benefits SENSORS / COIL ENCAPSULATION Coil encapsulation moves into the future with DuPont therm o p l a s t i c s . 9 S E N S O R / E N C A P S U L AT I O N RESINS - DuPont offers the most advanced technology a v a i l a b l e . Recent advanced materials developed by DuPont for encapsulation are detailed in the 8Sensors/Encapsulation 9 section of the materials chart in this brochure. A type 6.12 glass reinforced nylon, coded Z Y T E L ® F E5382 B K276 was developed for fine wire encapsulations for minimising coil distortion through soft-fill low-pressure injection moulding processing. A type 6.6 nylon, coded Z Y T E L ® F E5389 B K276 was also recently developed for thicker gauge wire and other electrical components. Quality part s : T h e r m o p l a s t i c components are lightweight, tough and durable. En v i ronmentally acceptable: The use of dipping varnish can be e l i m i n a t e d . C o s t - e ff e c t i v n e s s : A typical solenoid coil encapsulated with a DuPont thermoplastic costs up to 40% less than a similar epoxy unit. Faster cycle time: With thermo- plastics, less processing time is needed due to faster cycles and the elimination of secondary operations. P a rt consolidation: The increased design flexibility of thermoplastics often results in fewer parts and easier assembly through moulded- i n c o n n e c t o r s . Injection moulded engineering thermoplastics offer the cleanest, most cost-competitive encapsulation (overmoulding) technology available t o d a y. When compared to thermosets or epoxy compounds, thermoplastics such as DuPont Z Y T E L ® nylons or R Y N I T E ® and C R A S T I N ® p o l y e s t e r s o ffer outstanding electrical component cost advantages. Higher yields: T h e r m o p l a s t i c components require less material hence scrap sprues and runners can be reground and reused, resulting in higher material yields. 11 10 TestMethod PropertyConditionsISOUnits Stress at break527MPa Strain to break527% Tensile Modulus527MPa Charpy notched 23 °C179/1eAkJ/m 2 impact strength- 30 °C Charpy impact 23 °C179/1eUkJ/m 2 strength- 30 °C Melting temperature10 K/min3146 C°C Temperature of deflection Method A; 1.8 MPa75°C under loadMethod B; 0.45 MPa Coefficient of linearParallelASTM10 -4 K -1 thermal expansionNormalE 813 Comparative tracking indexIEC 112V Electric strengthP25/P75; 1mmIEC 243kV/mm Surface resistivityIEC 93ohm Volume resistivityIEC 93ohm cm Densityg/ml Flammability1.6 mmUL 94 0.8 mm Water absorption23 °C, equilibrium62% 23 °C, saturation 24 hrs immersion Moulding shrinkageParallel Normal P ro p e rties of candidate materials for e n c a p s ul a t i o n PA 66, unreinforcedPA 66, 30% glassPA 6.12, 33% glassPBT, 30% glassPBT, 30% glassPET, 30% glassPET, 15% glass toughenedtoughened, flame ret.toughened Z YTEL ® E103 HSLZ YTEL ® 70G30 HSLZ YTEL ® FE5382C RASTIN ® T805C RASTIN ® T845 FRR YNITE ® 530R YNITE ® 415 HP DAM50% RHDAM50% RHDAM50% RH 8759 (yield)20813516514010011015879 4.4 26 (yield)35554.23.735 3100150010000750070008500110004700 614141614.5111111 44141612.610118 NBNB889777567055 NBNB807389654525 213210254250 80254210190192224207 235260205205 0.220.220.30.30.30.23 1.071.071.21.2 525400500275250 31283832292735 E 14E 13> E 15E 131 E 15> E 14> E 14E 14E 13 E 15E 11> E 15E 11> E 16> E 16E 15E 13 1.141.141.371.371.321.501.691.561.39 V2V2HBHBHBHBHBV0 HBHBHB 2.91.90.90.140.100.20.25 8.5620.350.270.782.5 0.050.24 1.50.30.250.250.20.3 1.10.70.90.91.0 217 261 263 1.17 1.14 PA 66/6 blend,PBT, 30% glass 40% mineral, toughened M INLON ® 11C140C RASTIN ® SK605 DAM50% RH 8756140 10262.6 6000240010 000 6711 549 120NB56 808055 225 205 220 0.3 0.9 550450 362731 E 14> E 14 E 11> E 15 1.461.461.53 HBHBHB HB 1.80.13 5.70.37 1.40.3 1.41.0 13 12 General pro p e rties table PA 66, unreinforcedPA 66, 30% glassPA 66, 13% glassPA 6, 15% glassPA 66/6 CopolymerPA 66, 25% glass toughenedflame retardantflame retardant Z YTEL ® E103 HSLZ YTEL ® 70G30 HSLZ YTEL ® 79G13 LZ YTEL ® 73G15Z YTEL ® FR7200 VO FZ YTEL ® FR70G25 VO DAM50% RHDAM50% RHDAM50% RHDAM50% RHDAM50% RHDAM50% RH 8759 (yield)20813511867135758550 (yield)138110 4.426 (yield)354103.584202.02.6 3100150010000750051003700600035003900180095007500 61416168148143.510.510- 44141666814339- NBNB88976759578550NB43- NBNB807359545754656545- 8025424220475243 235260260220195 1.170.220.220.50.50.380.380.780.26 1.141.071.071.31.31.21.20.90.83 525400475600350 312838323735 E 14E 13 > E 15E 13> 1 E 15E 14 E 15E 11 > E 15E 11> 1 E 15E 12 > 1 E 15 1.141.141.371.371.211.211.231.231.191.191.49 V 2V 2HBHBHBHBHBHBVO (0.5 mm)VO (0.5 mm) 2.91.92.22.50.9 8.566.57.63.4 1.50.30.40.31.10.23 1.11.21.100.9 TestMethod PropertyConditionsISOUnits Stress at break527MPa Strain to break527% Tensile Modulus527MPa Charpy notched23 °C179/1eAkJ/m 2 impact strength- 30 °C Charpy impact 23 °C179/1eUKJ/m 2 strength- 30 °C Melting temperature10 K/min3146 C°C Temperature of deflection Method A; 1.8 MPa75°C under loadMethod B; 0.45 MPa Coefficient of linearParallelASTM10 -4 K -1 thermal expansionNormalE 813 Comparative tracking indexIEC 112V Electric strengthP25/P75; 1mmIEC 243kV/mm Surface resistivityIEC 93ohm Volume resistivityIEC 93ohm cm Densityg/ml Flammability1.6 mmUL 94 0.8 mm Water absorption23 °C, equilibrium62% 23 °C, saturation 24 hrs immersion Moulding shrinkageParallel Normal 263261262223255255 147 220 0.86 0.86 15 PBT, 30% glassPBT, 30% glassPET, 30% glassPET, 30% glassPET, 35% glass/micaPOM Homopolymer,POM Homopolymer,Engineering thermopl astic flame retardantlow warpageflame retardanthigh viscositymedium viscosityElastomer C RASTIN ® SK645 FRC RASTIN ® LW9030R YNITE ® 530R YNITE ® FR530R YNITE ® 935D ELRIN ® 100D ELRIN ® 500H YTREL ® 8238 1401351581358571 (yield)72 (yield)48.3 2.52.83227045350 12 000950011000120001020030003200 910118.56179 88118.54107 4050704025NBNB 4050453020-- 225225254254252177177223 21018222422420011511555 220215170170140 0.30.250.30.250.231.21.2 0.91.0 275550250250325600600 283535 33 39 32 32 > E 14> E 13E 14E 14E 14E 15E 15 > E 16> E 13E 15E 15E 15E 15E 15 1.691.431.561.671.581.421.421.28 VOHB VOHBVO (0.35 mm)HBHBHB 0.100.240.20.170.130.20.2 0.300.720.780.770.830.90.9 0.050.050.050.320.320.3 0.350.20.20.20.42.2 - 2.41.9 - 2.2 1.00.50.90.90.8 General pro p e rties table TestMethod PropertyConditionsISOUnits Stress at break527MPa Strain to break527% Tensile Modulus527MPa Charpy notched23 °C179/1eAkJ/m 2 impact strength- 30 °C Charpy impact 23 °C179/1eUkJ/m 2 strength- 30 °C Melting temperature10 K/min3146 C°C Temperature of deflection Method A; 1.8 MPa75°C under loadMethod B; 0.45 MPa Coefficient of linearParallelASTM10 -4 K -1 thermal expansionNormalE 813 Comparative tracking indexIEC 112V Electric strengthP25/P75; 1mmIEC 243kV/mm Surface resistivityIEC 93ohm Volume resistivityIEC 93ohm cm Densityg/ml Flammability1.6 mmUL 94 0.8 mm Water absorption23 °C, equilibrium62% 23 °C, saturation 24 hrs immersion Moulding shrinkageParallel Normal 14 N o t e s

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