Engineering Polymers for Electric Motors - cbucc.com

®

Engineering Polymers for electric motors

® DuPont registered trademark

DuPont Engineering Polymers

Front page: – General purpose motor from FHP Elmotor AB – Window lift motor from Meritor

Contents Page Introduction - Worldwide motor manufacture and DuPont's global team - The total DuPont offering - Traditional versus new approach - Vespel® - Automotive window lift motor - Significant cost savings

4 5 6-7 8 9 10

Electrical insulation and approved insulating systems from DuPont - UL 1446/IEC 85 Electrical Insulation Systems (EIS) - Thermoplastic encapsulation - Advantages of high temperature insulation systems - DuPont family of insulating materials

11 11 12 12

Motor design - Rotors and stators - Overmoulding - Commutators - End frames - Stiffness, strength and creep resistance - Bearings and bearing housings - Gears and gear housings - Brush holders - Motor cooling fans - Function integration - Assembly features - Frame extensions and housings - Interconnects - Motor design innovations - Noise, vibration and harshness

14 14 16 16 18-19 20-22 22 22 23 24 25 26 26 27 28

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DuPont's Global Motors Team can assist you whenever and wherever you need it Today's electric motor design teams are being confronted by more challenges than ever before. There is a particular need to develop more cost effective motors for an increasingly competitive marketplace. As a result, a new and broader range of engineering and insulation materials is changing the way in which motors are designed, manufactured and assembled. Global Motors Team To help you take full advantage of the latest materials and technology when you optimize an existing design or develop a new motor, DuPont has established a Worldwide Motors Team. By drawing on its global experience and resources, you are assured of proper material selection, part design and processing. The motors team can help you: • design motor components • with material selection • with processing support Global technical support DuPont has R&D, manufacturing, technical service and distribution facilities throughout the world. When you purchase engineering materials for electric motors, technical support is part of the offering. You have opened the door to a world of knowledge that can provide you with valuable practical help at every stage of your project. The DuPont technical centres, located in strategically selected regions around the world, can provide you with invaluable assistance. And DuPont will work with you from concept through to commercialization. DuPont's global offering for electric motors State-of-the-art insulation technology provides motor manufacturers greater design flexibility and the opportunity to reduce costs. DuPont offers you the largest range of electrical insulation systems, and each comes with a variety of approvals by testing agencies, including Underwriters' Laboratories, IEC and CSA. What's more, engineering polymers also provide many benefits in housing, motor bracket and bearing applications. These materials can reduce finished part costs through simplified assembly, parts integration, and lower material costs. Although this brochure concentrates on engineering polymers used in electric motors, DuPont's total offering goes far beyond this. It includes an extremely 4

broad range of elastomers, films, fabricated components, fibres, chemicals, refrigerants, advanced structural composites, electronic materials, and finishes.

equipment. Many of the examples used are just re-thinking of an old concept, but in each case new materials have met the needs of a designer, engineer or end-user.

This brochure illustrates many of the advantages and options that result from incorporating DuPont's engineering materials in your motor design. You will find ideas ranging from plastic bearings to extensions of thermoplastic motor frames, rotor insulation, and protective devices used in motor control

For more information on DuPont's family of engineering materials, contact your nearest DuPont office (see back page for contact addresses).

Engineering polymers Crastin® PBT thermoplastic polyester resin Delrin® acetal resin Hytrel® thermoplastic polyester elastomer Minlon® mineral reinforced nylon resin Rynite® PET thermoplastic polyester resin Zenite® LCP liquid crystal polymer Zytel® nylon resin Zytel® HTN high temperature nylon resin Fluoropolymers Teflon® fluorocarbon resins Tefzel® fluorocarbon resins Material for high performance bearings Vespel® polyimide parts and shapes Sheet structures for electrical insulation Nomex® brand sheet structures Lubrication Krytox® fluorinated oil and grease Films for electrical insulation Mylar® polyester film Kapton® polyimide film Wire & cable materials Elvaloy® Hytrel® thermoplastic polyester resin Kapton® polyimide film Teflon® fluorocarbon resins Tefzel® fluoropolymer ®

DuPont's registered trademarks.

5

Traditional universal motor construction The majority of motors produced today are still manufactured using large numbers of components in traditional materials such as paper or films for insulation, thermosets for brush holders, and die-cast metals for end frames. A significant proportion of the cost of the finished motor results from labourintensive assembly.

Tacho-generator (or encoder) screwed to die-cast end frame

Brush holder mouldings

Fixing screws for connector Separate connector mounting plate De-flashed and machined die-cast end frame Paper/tape insulation for stator windings

Separate connector moulding Field coils secured to laminations by pins or clamps

Individual paper or film slot insulators

Paper or film end insulators

End frame in metal or thermoset

6

Design utilizing the features of engineering polymers DuPont engineering polymers offer a better, more cost effective solution. High performance polymers, including Rynite® glass reinforced PET polyester, as well as Zytel® nylon, Zytel® HTN high temperature nylon, Crastin® PBT, Zenite® LCP and Minlon® mineral reinforced nylon, Hytrel® thermoplastic polyester elastomer and Vespel® polyimide parts facilitate parts integration. In addition, they provide superior thermal properties, thin-walled stiffness, processibility and:

• Parts integration and reduced assembly costs • Close part tolerances • Stiffness and dimensional stability • Reliable performance at high temperatures

• Efficient, reliable wire winding • Free UL and IEC recognition for materials and insulation systems up to Class R • No finishing or machining normally necessary

Snap-fits for tacho-generator (or encoder)

Integrated push-fit brush holder End frame moulded in Rynite® PET, Crastin® PBT, Zytel®, Zytel® HTN with integral brush holders and integral connector Vespel® thrust plug (see next page) Overmoulding acting as both coil former and stator insulation High performance lead wire insulation (e.g. Kapton® or Tefzel®)

Overmoulded rotor insulation. The insulation of slots, ends and shaft provides double insulation Hytrel® overmoulding to reduce noise and vibration

End frame moulded in Rynite® PET, Crastin® PBT, Zytel®, Zytel® HTN

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Vespel® The search for comfort and safety in the automotive industry has led to increased numbers of electric motors. These are now widely used to make driving more pleasant (window lift, sunroof, central locking, air conditioning actuation, seat, mirrors & steering adjustment), and safer (windscreen wipers, idle and exhaust controls, differential locking). Increasing regulations and specifications for equipment such as startermotors and fuel pumps place greater demands on mechanical wear and friction components. Parts such as bushings, washers and thrust plugs working in electrical motors have to withstand axial and radial loads coupled with speed. The wear and friction characteristics of Vespel® have helped electrical motor manufacturers to simplify their design while improving performance and life. Bushings Used in all kinds of electrical motors, Vespel® bushings can run with or without lubrication, depending on the application. A “straight” bushing design is adapted to radial loading but a “flanged” design can additionally bear axial loads and therefore eliminate the need for a washer.

Parts can easily be press-fitted into the housing while maintaining very good control of the inside diameter. In addition, the high PV capability enables the length of the bushing to be reduced. In these types of application, a low and constant coefficient of friction is required, as well as wear and creep resistance. The various Vespel® graphite filled grades provide cost effective solutions. Washers Washers take the axial load in electrical motors, which means that while providing wear and friction resistance as bushings do, they also have to withstand impact.

Thrust plugs Specifically used in windscreen wipers, window lift, sunroof, seat adjusting, differential lock motors, etc., thrust plugs are parts that are directly fitted into the rotor shaft with a slight interference. Like washers, these parts have to take axial loads, and resist creep and wear. Depending on the application, a low or relatively high coefficient of friction may be required, and unfilled SP 1 or SP 21 filled with graphite are the usual preferred choices. During very severe use, Vespel® thrust plugs will not melt, and therefore guarantee the function.

Due to the small loading area of such components, both pressure and velocity conditions can be high, generating excessive frictional heat. The creep resistance and the PV capability of Vespel® washers guarantee long and reliable life of the equipment. Noise, often generated by metallic parts running against each other, is eliminated.

Thrust plugs made out of Vespel® SP 1 are used in ITT’s powerful, reliable and economic automotive rear windscreen wiper motor.

8

Automotive window lift motor using DuPont engineering polymers DuPont engineering polymers and many other DuPont resins are ideally suited for automotive motor applications, as they greatly contribute to overall cost reduction by providing functional integration and weight reduction for most of the motor components. The window lift motor is a good example as illustrated in this drawing, but similar application possibilities can also be extended to other motors such as wiper motors, seat motors, sunroof motors, and many of the some 80 different motors we find in modern cars.

Almost all window lift gear housings today are in nylon such as Zytel® 70G30, for polyester PBT and PET resins like Crastin® PBT SK605 and LW9030 and Rynite® PET 940. Die-cast metals are still being used in some other motors, which are gradually being replaced by Zytel®, Crastin® PBT, and if higher mechanical strength at elevated temperatures is required, by Rynite® PET or Zytel® HTN.

Hytrel® is an excellent candidate for seals and hard/soft combinations. Vespel® is the ideal material for thrust plugs due to its excellent low wear performance. Insulation spiders can be moulded in Zytel®, Rynite® PET or Zytel® HTN. External parts such as connectors can be moulded in Zytel®, Crastin® PBT or Rynite® PET and integrated into the main body.

Delrin® 100 and Delrin® 100P with its unique combination of toughness, stiffness and superb friction and wear properties, has long been the classic gear material for automotive motor gears.

Connector seal - Zytel® HTN - Crastin® PBT - Rynite® PET

Insulation spiders - Zytel® nylon

Vespel® thrust plug

Cushion - Neoprene Vespel® thrust plug

Connector seal - Hytrel®

Gear - Delrin® Acetal

Gear housing - Zytel® - Crastin® PBT - Rynite® PET - Zytel® HTN

9

Significant savings Engineering polymers offer significant savings in electric motors. The higher raw material cost is normally more than offset by the production benefits, combined with a reduction in the number of components and lower assembly costs. Fig. 1, for example, shows some of the key areas where cost savings can be generated, using a motor end frame in Rynite® PET, Crastin® PBT, Zytel® or Zytel® HTN, rather than thermoset or die-cast metal. Additionally, these products provide all the design and assembly advantages associated with engineering polymers, resulting in further cost savings and a better product. For further assistance in making a detailed comparative cost estimate for your application, including materials, processing, finishing, assembly and production suitable for your operation, contact your local DuPont office (see back page).

10

Versus thermosets Rynite® PET, Crastin® PBT, Zytel®, Zytel® HTN offer:

Versus metals Rynite® PET, Crastin® PBT, Zytel®, Zytel® HTN offer:

• Superior mechanical properties allowing volume reduction of part

• Reduced part weight (also leads to lower transportation costs)

• Higher production rates

• No de-flashing

• Easier handling during processing and assembly due to superior toughness

• No machining

• Advantage of using regrind to minimize scrap

• 4 to 5 times the mould life for similar toolmaking costs

• No de-flashing

• Integrated colour, avoiding the need for painting

• Parts integration

• Parts integration • Minimal breakage problems with finished products during handling and shipping • Environmental friendliness due to recyclability Fig. 1

• Ability to provide double insulation • Attenuation of noise and vibration

Electrical insulation and approved insulating systems from DuPont The electrical insulation system of a motor consists of a number of major and minor components: Major • Ground insulation (e.g. slot and edge insulators) • Magnet wire • Dipping varnish • Phase separators Minor • Insulating tapes • Lead wire • Wire end sleeving • Tie cord • Wedges and other related parts UL 1446/IEC 85 Electrical Insulation Systems (EIS) A fundamental requirement for many motors is that they meet either UL 1446 or IEC 85 (EIS) requirements, or both (see Fig. 3). To meet this need, we have gained both UL 1446/IEC 85 recognitions for our engineering polymer resins in temperature classes from 130ºC to 220ºC. The DuPont EIS available to customers contain a wide range of tapes, sleeving materials, magnet wires and varnishes and are listed in the UL “Yellow Cards” (see Fig. 4 and Fig. 6) under “Plastic Materials and Electrical Insulation Systems (OBEU2) for UL 1446 and under “Insulation System Components,

electrical, evaluated in accordance with IEC publications (OCTU2)” for IEC 85. We continue to expand our number of recognized EIS, and as additional systems receive recognitions, they will be listed. We have also published an extensive brochure on EIS which is entitled: “Thermoplastics for UL/IEC Electrical Insulation Systems: Transformers, Motors, Coils, Relays and Encapsulation” available to customers from DuPont as publication H-74531. What are electrical insulation systems (EIS)? When designing a motor, for example, you have two basic ways of selecting the materials going into your product: you can pick the wires, tapes and the thermoplastics used either by the individual material thermal and performance recognitions, e.g. the UL relative thermal indices of each material by itself, or by the collective system recognition, which is a measure of how the group of materials selected behave together in a common environment. As an example, consider a simple coil form moulded in Zytel® 132F nylon used in a shaded pole motor. Both the wire and thermoplastic may be separately qualified in the thermal class required for this application. However, UL 1446/IEC 85 recognition of a system containing all the materials tested together helps build confidence the EIS used will produce a quality product for the global marketplace.

Other motor components that may be subject to EIS requirements include moulded thermoplastic spiders (see Fig. 2) used in armatures, overmoulded stator insulation, and separate stator components. Thermoplastic encapsulation Motors are beginning to see the use of thermoplastic encapsulation, particularly in stator insulation. Being replaced are the tapes, films, etc. that are used in conventional motor insulation, as well as the epoxy potting used in some constructions. Complexity of encapsulation can vary from small stator coils to larger and more intricate motors such as the Pacific Scientific encapsulated stators (see photo H, page 15). Using the steel laminate covers as an insert, the stator is made in a one-step overmoulding operation. Encapsulation provides slot and end insulation, termination holders, contour supports, and guide posts for windings – all in a single moulding step. Additional information on thermoplastic encapsulation can be found in “Electrical/Electronic Thermoplastic Encapsulation” available from DuPont as publication H-58633.

Fig. 2 - Rotor end-insulators in Rynite® PET FR530 used by Braun (Spain).

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Advantages of high temperature insulation systems By designing a motor to operate at high temperatures, one of two benefits can be gained: reduced size for a given power output, or increased power output for a given size. With the ability of Rynite® PET to perform in insulation systems up to Class N, it is normally possible to use it to upgrade the rating of a motor at little or no additional cost. The DuPont family of insulating materials

Maximum temperature at hottest spot

UL 1446 temperature classes

IEC85 temperature classes

Maximum temperature at hottest spot

130°C 155°C 180°C 200°C 220°C 240°C >240°C

B F H N R S >240°C

Y A E B F H 200 220 250 *

90°C 105°C 120°C 130°C 155°C 180°C 200°C 220°C 250°C *

*Above 250, each class is a temperature of 25°C higher than the preceding one: i.e. 275, 300, etc.

DuPont offers you an extremely wide range of insulating materials. Crastin

®

Fig. 3

PBT

These thermoplastic polyester resins feature excellent processibility, toughness, and good electrical properties. They are used in connectors, coil forms, and other electrical components.

UL Class

Temperature rating

A

105°C

Rynite® PET, Zytel® nylon

Mylar®, Nomex®, Kapton®

Rynite® PET thermoplastic polyester resins offer an excellent combination of thermal stability, electrical properties, dimensional stability, and stiffness for today’s small, more complex electrical and electronic components. Rynite® PET is widely used in coil forms and encapsulation.

B

130°C

Rynite® PET, Zytel® nylon Crastin® PBT


F

155°C

Rynite® PET Crastin® PBT Zytel® nylon Zytel® HTN


Zytel®, Zytel®

H N R

180°C 200°C 220°C

Rynite® PET Rynite® PET Zenite® LCP

Nomex®, Kapton® Nomex®, Kapton® Nomex®, Kapton®

Rynite®

PET

HTN

Over half of all coil forms used worldwide are in unreinforced and glassreinforced nylon. Zytel® HTN (High Temperature Nylon) resins are high temperature nylon copolymers with a 300°C melting point and a 125°C glass transition temperature (dry). Zytel® HTN is used in applications requiring high strength and high temperature capabilities. Zenite® LCP Liquid Crystal Polymer Zenite® LCP resins are aromatic polyester resins with high (335-352°C) melting points. Features include excellent dimensional stability and creep resistance, even at very high temperatures. Their processibility makes moulding surface-mount coil forms with 0.25 mm thick flanges a commercial reality.

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Moulded engineering polymers

Films

Fig. 4 Nomex® brand sheet structures

Kapton®

These sheet structures offer high temperature resistance, superior dielectric properties and high tensile strength, combined with excellent flexibility and resilience. Available in strip and sheet form, Nomex® provides superior layer and phase insulation between coil layers and around coil formers.

An ultra-tough polyimide film capable of withstanding extreme temperatures (400°C) and pressure, it is impervious to most chemicals. As an insulator, Kapton® has unmatched dielectric properties and remarkable tensile strength, which permit thinner wall construction for increased performance and cost efficiency.

Mylar® This exceptionally strong polyester film offers an unusual balance of chemical, electrical, physical and thermal properties. Well suited for many electric, electronic and industrial uses, Mylar® provides superior interwinding barrier and phase insulation in wire and cable coils.

Fig. 5 - RTI versus HDT of DuPont Engineering Polymers (30-35% glass-reinforced) 250 ¡C

Relative thermal index

Zenite® LCP 200 ¡C

Rynite® PET

150 ¡C

Crastin

®

PBT

Zytel® HTN Zytel® PA66

100 ¡C 200 ¡C

250 ¡C

Heat deflection temperature at 264 psi, °C

Fig. 6. - Examples of a pre-approved Class F (155°C) insulation systems based on Rynite® PET and Zytel®.

13

Motor design Rotors and stators Engineering polymers such as Rynite® PET, Crastin® PBT, Zytel®, Zytel® HTN and Zenite® LCP are well suited to motor insulation, as shown in the preceding section. These moulded insulators make motor assembly easier, and reduce labour costs. Several examples of applications are shown here. Overmoulding There is a cost efficient technique for insulating rotors and stators which has not been discussed, and that is overmoulding – where the lamination stack (preferably pre-heated) is inserted into a mould and selectively coated with plastic.

Overmoulding is normally used to avoid the need for separate insulator mouldings and/or pieces of insulating film. Consequently, this technique can offer further cost savings and production advantages.

It is sometimes useful to employ flow leaders to aid in material flow. These can be holes a few millimetres in diameter through the rotor or stator lamination stack. These leaders aid the flow of thermoplastic and promote complete filling of thin sections.

The thickness of thermoplastic required, particularly in the case of overmoulded slot insulation, is very small (typically <1 mm). As a result, one of the most important considerations when designing such insulation is the ability to fill the plastic part completely during the moulding operation. Complete filling is critical to eliminate any possibility of dielectric failure when the part is operational. Therefore, material selection is very important. Grades of Rynite® PET and Zenite® LCP offer particularly low melt viscosities (high flow), and Rynite® PET offers excellent insulation performance (up to Class N = 200°C) and Zenite® LCP (Class R = 220°C).

B

E

14

I

A. Grundfos (Denmark) stator insulators moulded in Rynite®. B. Multi-functional armature insulators, also known as spiders, in Zytel® HTN, for windshield wiper motors from ITT. C. Motor stator insulation in Zytel® 70G30 for Elco (Italy). D. Mycalex (UK) shaded pole motors with coil bobbins and terminal block moulded in Rynite® PET FR530. E. Sanyo (Japan), overmoulded stator bobbins in Rynite® PET FR530 and FR515 for permanent magnet stepping motors.

A

F. Miele (Germany) stator insulation made of Zytel® 101L. G. Stator encapsulation of 25-W shaded pole AC induction motor for Electric Motors and Specialties, Inc. (USA). H. Encapsulation of motor winding insulation, end frame and connector housing in Rynite® PET for Pacific Scientific (USA). C

I. Asynchronous motor shaft overmoulding for SEL (Germany), Rynite® PET (Class H). D

G

F

H

15

Traditionally, materials such as stamped steel, die-cast aluminium or zinc alloys, and thermosets have been used for motor frames. However, these materials have limitations in terms of weight, function integration, environmental friendliness, assembly, noise and vibration.

Commutators Commutators require insulation between the bars as well as at the ends. A traditional way of providing this insulation is with mica sheet, as shown in Fig. 7. However, as with rotors and stators, the insulation can often be provided more cost effectively by engineering polymers. A material with good flow characteristics – to completely fill thin part sections in the mould – and good high temperature insulation performance is normally required. Rynite® PET meets both of these requirements.

Engineering thermoplastics not only offer the required mechanical properties, but also permit weight savings, functional integration and eliminate the shortcomings of metals and thermosets. This capability results in a reduction of the number of components, and consequently in lower finished part cost.

For larger commutator applications where the requirements for high flow, dimensional stability and high temperature resistance are even more demanding, Zenite® LCP provide an excellent balance of properties.

The answer is normally yes, provided that the right engineering polymer is selected for the task, and that correct design and ribbing techniques are employed.

A

End frames It is well recognized that most motor end frames are demanding engineering applications. The air gap between rotor and stator is usually less than 1 mm, so rotor alignment is critical.

B

16

Naturally, when an end cap, a motor bracket, or even a complete housing is being designed, the same question is often raised: “Does a thermoplastic have sufficient stiffness and dimensional stability for this application?”

A. Vacuum cleaner motor end frame in Rynite® PET and Crastin® PBT from Electrolux (U.K.). Tightening nut Iron ring Mica V ring Front V ring Commutator bars Mica Iron shell

Commutator bars Mica insulation between bars

B. Commutator plates moulded in Zytel® nylon for Maxon motor (Switzerland). C. Fiat rear screen wiper motor frame in Rynite® PET FR530. D. Zanussi dish washer pump motor frame in Rynite® PET FR 530 from Sole (Italy). E. Thrige-Titan (Denmark) forklift truck motor end frame in Rynite® PET 530.

Back V ring with mica inner and outer rings for insulation

F. Rexon (Taiwan) mitre saw motor frame/housing in flame-retardant, glass-reinforced Zytel®.

Fig. 7

C

D

E F

17

Tensile strength MPa

500

Die-cast materials 400

Zn

300

Al Mg

Reinforced thermoplastics Zytel® HTN 51G35

200

Rynite® PET 555 Unreinforced ® Zenite® LCP Rynite PET 530 thermoplastics Crastin® PBT SK 605 ® Zytel 70G30 HSL 100 30% GR PC PA66 Delrin® (POM) PA612 PC PBT PA11 ABS PP 1

5

Thermosets moulding compounds 10

50 100 Flexural modulus GPa

Fig. 8 - Stiffness/strength combination of materials.

Zenite® Rynite® PET 545 Crastin® PBT SK605

Zytel®

LCP

6130

51G35 Zytel® 70G30 HTN

Zinc-Al

The stiffness and stability of thermoplastics have now been confirmed by experience in commercial applications. However, when a new motor frame is being developed, a finite element analysis (FEA) is often valuable in optimizing the design. As shown in Fig. 8 and Fig. 9, glassreinforced engineering polymers are particularly well suited to motor frame applications. Rynite® PET absorbs only extremely small quantities of water following moulding, giving it excellent dimensional stability. It also has a high heat deflection temperature. In addition, these resins can be modified with mineral additives to further increase dimensional accuracy for very demanding applications.

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Flexural modulus MPa

Examples of finite element analysis for a motor frame: Top photo shows deflection in a Y direction in mm. Bottom photo shows stress in N/mm2.

Mg Delrin®

Zytel® 101

1

1.5

2.5

2

Thickness (mm) h2

h1 8h 1

Metal Fig. 9 - Beams of equivalent stiffness.

8h 2

Plastic

3h 2

Components of automotive motors such as the windowlift motor shown on this page or windshield wiper motors and seat motors can be subjected to considerable stresses which over time will cause creep. For example, the gear housings of these motors have to withstand external and rotor shaft forces over thousands of cycles. Coupled with relatively high temperatures even in the interior of a car, these forces can lead to creep of the material. Glass reinforced grades of Zytel®, Crastin® PBT, Rynite® PET and Zytel® HTN have good creep resistance to withstand this.

Creep resistance Deformation under load with time is called creep. The amount of creep depends on material composition (polymer type, reinforcement, etc.), time, temperature and the applied stress level. The data shown in Fig. 10 indicate that glass-reinforced engineering polymers have particularly good resistance to creep, even at high temperatures and stress levels.

2.2 For comparison Zytel® 101F 23°C/20 MPa stress

2.0 1.8

125¡C Rynite® PET 530

Strain (%)

1.6 1.4

125¡C * Zytel® 70 G30 HSLR 60¡C Rynite® PET 530

1.2 1.0

125¡C 23¡C 23¡C 23¡C

0.8 0.6

Rynite® PET 555 * Zytel® 70 G30 HSLR Rynite® PET 530 Rynite® PET FR 530

0.4 0.2 0 1

10

100

1000

10000

Times (hours) * It is critical to note that for Zytel® 70 G30 HSLR: 23°C = 50% RH, 125°C = DAM

Fig.10 - Long-term creep data (at 27.6 MPa stress)

19

Bearings and bearing housings In micromotors, the end cap itself, frequently made of thermoplastic, often also acts as the bearing. Thermoplastic bearings can offer a number of advantages over bearings in metal, including: • Ability to operate with minimal or no lubrication • Longer wear life • No corrosion by chemicals and lubricants • Noise dampening and reduced vibration Plastics commonly used in these types of bearings are Zytel® and Minlon® nylon resins, and Delrin® acetal resins. As plastics do not conduct heat readily from the frictional source, heat dissipation is a major consideration in the design of thermoplastic bearings. For an initial evaluation of whether a plastic bearing will perform in a specific application, the PV concept (Pressure x Velocity) rating can be used. The PV value is defined in the following way (see Fig. 11): Specific bearing load: F (MPa) p= dxl Peripheral speed: d x ¸ x n (m/s) v= 1000 PV value:

For bearings which require very low coefficients of friction and higher PV values, standard engineering polymers can be modified with, or replaced by, Teflon® and Tefzel®. Full details of these PV calculations, together with advice on designing bearings in Zytel® and Delrin®, are available within separate design brochures. If you need assistance, please contact your nearest DuPont office (see last page).

P d = Shaft diameter mm l = Length of bearing mm V = Peripheral speed m/s F = Overall load N n = Revolutions per s

V

l

d

Fig. 11

PV = pv (MPa – m/s)

20

The benefits of thermoplastic bearings can sometimes be brought to larger motors, but traditionally these motors employ metal bearings press-fitted into a metal frame (see Fig. 12). This arrangement gives a good interference fit over the full range of operating temperatures, as the bearing and bearing seat have similar coefficients of thermal expansion.

Maxon motor with bearings/end-caps in Minlon®

When a thermoplastic motor frame is used with a metal bearing, attention must be paid to the bearing seat design, as the thermal expansion of most polymers is considerably greater than that of metals. However, for most motors, attention to dimensions and proper interference fit for the plastic will provide good bearing alignment over the required range of operating temperatures. Thermoplastics also allow easier parts assembly, including the use of snap-fits. A number of new designs for thermoplastic bearing seats have also been developed for use with conventional bearings (see Fig.13).

Metal frame

Engineering polymers (glass-reinforced frame)

• High E-modulus

• Lower E-modulus

• Small increase in interference gives large increase in specific pressure on external ball bearing cage

• Large increase in interference gives small increase in specific pressure on ball bearing cage

• Dynamic interference required = 0.08% = 0.02 mm; resulting specific pressure = 18.8 MPa • Low permitted interference means tight tolerances required • Machining of bearing tolerance seat needed

• Interference for equivalent specific pressure = approx. 1% = 0.26 mm • Even with 1% interference, there is a safety margin since elongation to break of glass-reinforced engineering polymers is around 2.5-3% • Precision moulding total tolerance achievable for 26 mm = 0.1 mm • Required bearing seat tolerances can be achieved by moulding • Machining of bearing seat avoided • Lower temperature of the bearing, due to low heat conductivity of the polymer frame, gives longer lifetime

Fig. 12

Finger spring washer

Spring ring

Spring washer (slotted or not)

Olive bearing

Ball bearing

Elastomer part (self alignment vibration and noise reduction)

Housing

Housing

Housing (snap-fit)

Fig. 13 21

For the most demanding applications, additional techniques have been developed. One of these, patented by SKF, involves the overmoulding of a metal coil. As the coil has a rate of thermal expansion similar to that of the bearing itself, it keeps the play between bearing and housing to a minimum. This is achieved by preventing free expansion of the bearing housing with temperature variations. Experience has shown that this overmoulded insert is particularly useful for those applications where the range of operating temperatures is very wide. DuPont also offers materials such as Vespel® SP polyimide for very high performance bearings. Gears and gear housings Automotive motors, such as window lift motors and wiper motors, use gears and gear housings (see A and B). Engineering polymers are increasingly being established as the most suitable material for these applications. For example, Delrin® 100 is widely used in gear applications. Depending on the dimensional stability and thermal requirements, gear housings can be moulded in Zytel®, Crastin® PBT, Rynite® PET or Zytel® HTN (see Fig. 14).

Brush holders With a metal motor frame, it is normally necessary to have separate plastic mouldings to insulate the brushes and brush holders from the frame. A typical example is shown in photo E. Engineering plastics have the required electrical and thermal properties to perform well in such applications. Tracking resistance (CTI) is particularly important. However, another advantage of thermoplastic motor frames is that they avoid the need for these separate mouldings. The brush holder supports can be moulded as integral parts of the end frame, allowing the brush holders to be directly push-fitted into the frame (see page 7). This clearly reduces component and assembly costs.

In some larger motors, the brushes can rise significantly in temperature during operation. Here, it is important to design the area of the plastic bracket acting as the brush holder support for maximum ventilation. This can be done easily. In some applications, it is necessary to insulate the exposed end of the brush holder. A simple plastic cover can be designed to snap onto the motor frame to provide this insulation. This snap fit may be designed as permanent, or recoverable – to permit maintenance or replacement of the brushes. Once again, a design which permits maximum ventilation of the brushes is recommended.

During motor operation, the brushes become hot, but plastics are good thermal as well as electrical insulators. In some small motors, the temperature rise is not significant, and the brushes can be located directly in the moulded motor frame, as shown in photo H. However, many motors require metal brush holders. These are often made of brass and can be similarly push-fitted directly into the plastic frame.

C

A

I

B

22

I

C. Cut-away view of plastic motor frame using the overmoulded SKF insert.

Motor cooling fans Many motors incorporate their own cooling fans, to increase air flow and reduce operating temperatures. Traditionally these fans have been made of metal, but they can also be cost effectively moulded from engineering polymers.

D. Thrige-Titan forklift truck motor frame in Rynite® PET 530 using the overmoulded SKF insert. E. Brushes fitted directly into motor frame of Zytel®.

Normally, materials used for these applications are often the same as those used to mould the motor's insulation, or end frame.

F. Paris-Rhône (France) automotive alternator, using fan, brush holder and diode support plate moulded in Rynite® PET 545.

Zytel® HTN 51G45 100¡C

Rynite® PET 545

23¡C

G. Snap-fit bearing design used by Stebel (Italy) for their horn compressor motor in glass-reinforced Zytel®.

Crastin® PBT SK609 Zytel® 70G50

H. Snap-fit bearing design used with a motor frame in Rynite® PET for a Zanussi dish washer pump from Sole (Italy).

Zytel® 73G50 0

0,05

0,1

0,15

0,2

Def. (mm)

Zytel® data at 23°C at 50%RH

Fig. 14 - Deformation comparison of engineering polymers Wiper motor gear housing – concept study (45%-50% GR)

D

I. Flame retardant Rynite® PET was selected for this cooling fan from Japan Servo because of its good dimensional stability and heat resistance. Temperatures in photocopy machines can often reach 150°C.

E

F

H

G

23

Function integration

A. Traditional motor assembly.

Function integration and minimizing assembly costs are becoming increasingly important in today's competitive market. However, motor frames have traditionally been multicomponent assemblies.

B. Motor design based on engineering polymers, showing function integration. C. Multi-functional motor frame in Zytel® FR51 from Braun (Spain).

A major advantage of redesigning motor frames in thermoplastic is the ease with which one component can be designed to perform the functions of many.

D. Easy-assembly motor bracket in Minlon® 11C140 from Maxon (Switzerland).

The integration of some functions, such as brush holders, has already been discussed. This section concentrates on other features which can also be incorporated into motor frames.

E. Braun selected Zytel® for the motor end-frames of a recent handmixer because of its long term temperature resistance, excellent dimension stability and overall mechanical performance. A

C

24

Assembly features Motor frames are normally assembled to each other, or to the stator laminations, using bolts or metal clips, but this is a relatively expensive method of assembly. Thermoplastic end frames lend themselves to more efficient assembly techniques, such as snap-fits, interference-fits or ultrasonic welding. Some examples of these assembly techniques are illustrated in Fig. 15 and Fig. 16. They are particularly suited to smaller motors which have small applied loads, where they can offer valuable cost advantages.

B

Fig.15 - Plastic motor frame assembly using ultrasonic welding.

Fig. 16 - Plastic motor frame assembly using snap-fit.

D

E

25

Frame extensions and housings Motor frames can often be readily extended to fulfil additional functions. The availability of a wide range of DuPont engineering polymers with suitable properties for multifunctional parts means that motor systems can be designed to make products much more competitive in the marketplace. Minlon® can give high-speed fans used in vacuum cleaners the flatness required to generate a constant airflow, and the impact resistance needed to prevent breakage by incoming objects. Its warp-free mouldability and excellent dimensional stability also allow it to be used for multifunctional parts in the same appliances, reducing costs in components and labour.

Interconnects Materials such as those recommended for motor frames, e.g. Rynite® PET, Crastin® PBT and Zytel® polyamide, are widely used for connector applications. By moulding the electrical connector as an integral part of the motor frame, a number of separate connectors are usually eliminated. These may include a metal mounting plate, the separate connector moulding, and two or more assembly screws.

A. Myson (U.K.) uses Rynite® as both housing and insulation for this pump motor. B. Milwaukee (U.S.) power tool has motor frame and housing incorporated into a single moulding of glassreinforced Zytel®.

A

The heat buildup of fully enclosed motors requires the use of high temperature class polymers. Rynite® PET, Crastin® PBT, Zytel® HTN can meet these demands reliably, acting as both motor insulation and housing. Glass-reinforced Zytel® gives designers high strength, stiffness, very high deflection temperatures, rigidity, tensile strength, dimensional stability and impact strength. Just what they need to combine a motor frame and housing into a single unit.

A

Here are some examples of commercial applications.

B

26

Motor design innovations Fisher & Paykel Co, of Auckland, New Zealand, the country’s leading appliance manufacturer, has developed a radically new type of power drive for washing machines. This new “Smart Drive” incorporates multifunctional components made of DuPont Rynite® PET thermoplastic polyester resin, and is used in the company’s top-loading automatic washers. The Fisher & Paykel design replaces the conventional U.S. washing machine’s combination of a fixedspeed a.c. motor and a 40- or 50-piece gear case with a system using an electronically controlled brushless d.c. motor that drives the agitator and spin bowl directly through a patented clutch. The washing machine’s motor design is most unusual. Windings are located on the stator rather than on the rotor, and the rotor turns around the outside of a centrally mounted stator rather than inside it. This approach allows a direct mechanical link between the rotor and a common shaft to drive both spin and agitator movements.

The wheel-shaped part that comes out of the mould needs only windings and terminations to become a fully finished stator. It measures 25 cm across, and has 42 integrally moulded winding poles spaced around its circumference, as well as moulded-in wire ways, terminal holders and holes for mounting bolts and drainage. A three-phase winding is applied in a separate, fully automated step.

Assembly of the rotor and stator is simplicity itself. The stator is first bolted onto the washer’s outer bowl, which is accurately located over a bearing supporting the spin basket and agitator shaft. The rotor is then placed over the spline near the end of the drive shaft, and pulled down into position with a securing nut. At this stage, the motor is ready for electrical connection to the washing machine’s electronic controls.

The rotor is a dish-shaped component 27 cm in diameter. Integrally moulded teeth at its hub serve for spline mounting on the end of the shaft that spins the washer tub and moves the agitator. Spaced around the rotor’s circumference are 56 rare-earth permanent magnets, which are bonded to a ringshaped stack of steel laminates.

The Rynite® PET resins selected by Fisher & Paykel meet a rigorous combination of structural, dielectric and manufacturing requirements. The dimensional stability of Rynite® PET allows both the rotor and the stator to be moulded without the need for further machine processes.

The rotor is made by placing the laminate stack and attached nonmagnetized rare-earth strips in the mould, and then overmoulding with Rynite® PET, leaving the magnet strips exposed. These are subsequently activated by placing the rotor over a high-energy magnetising head.

The rotor withstands dynamic torsional and radial loading as it oscillates at variable speeds within a 200-degree arc during agitation cycles, and it whirls at speeds up to 1 100 rpm during spin cycles. These requirements are met with Rynite® PET 545 and FR543 for the rotor and stator, respectively. Rynite® PET FR543 is recognized by Underwriters Laboratories as UL 94 V-0 at 0,8 mm and 5-V at 1,6 mm.

The stator’s entire support structure, its ground insulation and coil supports are produced of Rynite® PET in a single injection-moulding step. A ring-shaped stack of specially profiled stamped steel laminations is placed in a mould and then injection overmoulded with the polyester resin.

C

C

C. An innovative brushless d.c. washing machine motor relies on Rynite® polyester for both insulation and structure in the wheel-shaped stator and the dish-shaped rotor.

C

27

Noise, vibration and harshness Two increasingly important factors in the design and marketing of motors are vibration and noise, particularly for such applications as office equipment and household appliances. Although product design has a major influence on the noise of a motor, there are a number of areas where materials selection can also play an important role. For example, the use of thermoplastic bearings wherever possible can reduce vibration and help to dampen noise.

The right material choice for the motor frame is also important. An application where Rynite® PET replaced a die-cast motor frame, allowing both cost savings and quieter performance, is shown in photo B. Further noise reduction is possible by isolating the motor frame from its normal mounting points, thus preventing the transmission of vibration. This can be achieved by using mounts moulded from a thermoplastic elastomer, such as Hytrel®. Several design concepts suitable for such applications as office equipment fans are shown in Fig. 17 and Fig. 18. Transmission of vibration can also be reduced by modifying gears. In the French food processor shown in photo A, a small gear moulded in Hytrel® has reduced the operating noise level of the appliance by 15 dB. The part in Hytrel® replaces a gear in acetal.

When dealing with noise problems of plastic components, it is important to understand the source of the noise, i.e. what is causing the part to vibrate, as well as to understand how the part itself is resonating before a solution is possible. The DuPont NVH laboratory was set up to deal with the noise problems of plastic components. It has portable NVH test equipment, making it possible to analyze a component in situ. For a more detailed analysis, samples are taken back to the NVH laboratory and excited using a relevant test rig. The components response to the excitation can then be measured by using techniques such as acoustic or laser holography. This testing helps to identify how the part needs to be modified so as to reduce the noise problem. Sample components can then be modified inhouse and supplied to customers for testing. The facility can test vibration and noise properties of electrical motors using various materials for the housing. A whole system can also be analyzed, such as the door mechanism on which a window-lift motor has been mounted.

B

28

A

A. Gear of flexible Hytrel® reduces noise by 15 dB in this appliance from SEB (France). B. Torin (UK) fan housing and bearing (overmoulded PCB) in Rynite® PET FR530. C. Hytrel® is used for blower mountings to provide quieter computer storage sub-systems. It offers excellent sound deadening properties, can absorb and isolate impact shocks, as well as being easy to overmould onto steel.

C

Ventilator mounting for vibration isolation

Steel sheet Ventilator housing

Ventilator

Sheet-iron Fig. 17 Fig. 18 29

®


Product guide and properties for electric motors

® DuPont registered trademark

Test performance ratings of DuPont Engineering Polymers Tracking Resistance, IEC 112 / UL 746 A

Crastin® PBT

Delrin® acetal

Rynite® PET

2

V (volt) thickness of specimens: >3 mm CTI IEC

UL 746 A PLC level

CTI-M IEC

S600F10, S600F20, S620F20 ST820 SK601 SK602 SK603 SK605 SK608 SK609 LW9130 LW9020, LW9030 T805 SO653 SO655 HTI619 S650 FR S680 FR T850 FR SK641 FR SK642 FR, SK 645 FR SK643 FR CE7931 SK673 GW LW9020 FR LW9020 FR GY LW9030 FR LW9320 FR LW9330 FR LW9330 FR GYB T841 FR T843 FR T845 FR HTI681 FR HTI668 FR HTI688 FR

>600 >600 300 350 400 450 475 500 400 550 500 300 250 >600 225 250 >600 225 250 250 250 250 350 325 375 350 375 350 250 275 325 >600 >600 475

2

350 >600 200 200 200 200 200 200 200 175 200 200 200 200 175 175 275 175 175 175 150 175 175

0 0 1

450 200 250

100, 107 100 P 500, 507 500 P, 900 P 100 ST, 100 T, 500 T, 570 500 CL, 500 AF

>600 >600 >600 600 600 >600

0 0 0 0 0 0

>600

520 530 545 555 935 FR515 FR530 L FR543 FR943

250 250 250 200 3251) 275 250 250 225

3 2 2 3 2 3 2 2 2

2 2 2 1 1 2 1 1 2 2 0 2

2 2 3 2 2 2 2 2 1 1 3

175

175

600

200 250

125 125 100

Zytel® PA66 unreinforced

Zytel® PA66 glass reinforced, flame retardant Zytel® PA66 glass reinforced

Zytel® PA66 mineral reinforced, flame retardant Minlon® PA66 mineral reinforced

CTI IEC

UL 746 A PLC level

CTI-M IEC

E101 L 101 F E103 HSL E103 HSL BK-80 105 F BK-10 114 L BK-97 135 F E42 A 450 490 ST801 NC-010, NC-010 A

>600 >600 525 (425) 525

0 0 0

375 (325) 575 (475) 400 (350) 400

FR70G28 V1 FR70G25 V0 79G13 L 70G20 HSL, 70G25 HSL 70G30 HSL 74G33E HSL BK-354

300 325 475 400 (325) 400 (325) 450

2 2 1

150

1

350

325

2

2501)

575 550 (475)

1

250 (200) 300 (250)

FR70M30 V0 10B140 11C140

575 (525) 600 600 (590) >600 >600

0 0 0 0 0 0 0

475 525 (475) 475 600

Zytel® PA66/6 unreinforced, flame retardant

FR7200 V0F

575

0

Zytel® PA66/6 glass reinforced, flame retardant

FR72G25 V0 FR72G25 V0 BK

325 275

3

Zytel® PA66/6 glass reinforced

72G30 L

Zytel® PA6 glass-mineral reinforced, flame retardant

FR73GM60 V0F FR73GM60E V0F FR73GM50 GWF

>600 >600 >600

0 0

Zytel® HTN high temperature nylon

HTN 51G35 HSL NC-010 HTN 51G45 HSL NC-010 HTN FR51G35 L NC-010

>600 >600 500

0 0 1

300 (250) 250 225

Hytrel® thermoplastic polyester elastomer

5556 7246

>600 >600

0 0

575

Zenite® LCP liquid crystal polymer

6130 WT-010 7130 WT-010 6330 NC-010

150 150 150

4 4 4

100 100 100

Vespel® polyimide resins

SP-1, SP-21

1) KC, KB values.

* Only available in black.

150 150

1

3

Caution: Colours often significantly affect tracking values in one or the other way. Further information on this is available on request. All the above information is subject to the disclaimer on the back page of this brochure.

3

Flammability classification, UL 94 UL rating at minimum thickness (mm)

HB Crastin® PBT

S600 F10, S600 F20, S620 F20 ST820** SK601, SK602, SK603 SK605, SK608**, SK609 LW9130 LW9020, LW9030 T805 SO653, SO655 HTI619 S650 FR, S680 FR T850 FR SK641 FR, SK642 FR SK643 FR, SK645 FR CE7931 SK673 GW** LW9020 FR. LW9030 FR T841 FR, T843 FR, T845 FR HTI681 FR HTI668 FR, HTI688 FR

1,5 1,5 0,8 0,8 0,8 1,5 0,8 1,5 1,5

Delrin® acetal

100, 107 500, 507 500 CL, 500T 570

0,8 0,8 0,8 0,8

Rynite® PET

520, 415 HP, 935 530, 545, 555, 408 FR515 FR530 L, FR943 FR543 9082 F**, 9085 F**

0,8 0,8


Zytel® PA66 glass reinforced, flame retardant

4

E101 L, 101 F, E103 HSL 105 F BK-10 114 L BK-97 135 F 408, 450, 490 ST801

V-2

V-1

V-0

5VA

0,8 1,5 1,5 0,8 1,5 1,5 1,5 1,5 0,8 1,5

0,86 0,35 0,81

1,5 1,5 1,5

0,82) 0,84) 0,84) 0,8 0,84) 0,8 0,8

FR70G28 V1 FR70G25 V0

1,47 0,5

Zytel® PA66 glass reinforced

79G13 L, 70G20 HSL, 70G25 HSL 0,8 70G30 HSL, 70G30 PSR 0,8 70G35 HSL 0,8

Zytel® PA66 glass-bead reinforced

70GB40 HSL

Zytel® PA66 mineral reinforced, flame retardant

FR70M30 V0

0,75 1,5

1,5

UL rating at minimum thickness (mm)

HB Minlon® PA66 mineral reinforced Zytel® PA66/6 unreinforced, flame retardant

10B140** 11C140

V-2

V-1

V-0

5VA

0,83) 0,81)

FR7200 V0F

0,5

Zytel®

PA66/6 glass reinforced, flame retardant

FR72G25 V1 FR72G25 V0

0,75

0,5


72G15 L, 72G30 L 72G40 HSL BK*

0,8 0,8


7335 F

1,5


73G15, 73G20, 73G30, 73G50

1,5

Zytel® PA6 mineral and glass reinforced, flame retardant, halogen and phosphorus free

FR73GM50 GWF**

Minlon® PA 6 mineral reinforced

73M30

0,85



0,8 0,8

FR73GM60 V0F, FR73GM60E V0F


6130 WT-010 7130 WT-010 6330 NC-010


4056 5556 7246


SP-1 SP-21

1) UL yellow cards are available.

** Only available in black.

2) DuPont test results using ISO 9290.

** Only available in natural colour.

1,50

1,5 1,5

0,8 0,41 0,8 1,5 1,47 1,47 1,47 0,8 0,8

1,7 1,6

3) NC, BK. 4) All colours.

Table for information only. For actual classification, please consult the most recent UL Yellow Cards.

5) NC, BK, GY.

For products or grades that do not appear on this table, please contact your DuPont representative for more information.

All the above information is subject to the disclaimer on the back page of this brochure.

5

Glow Wire Flammability Index: “GWFI” °C 1 mm Crastin® PBT

S600, S620 ST820 SK602, SK603, SK605 SK608, SK609 LW9130 LW9020, LW9030 T805 SO653, SO655, HTI619 S650 FR, S680 FR T850 FR SK641 FR, SK642 FR SK643 FR, SK645 FR CE7931, SK673 GW LW9020 FR, LW9030 FR T841 FR, T843 FR, T845 FR HTI681 FR, HTI668 FR, HTI688 FR

2 mm 700

960 960 960 960 960

3 mm 750 700 750 750 750 650 750 750 960 960 960 960 960 960 960

Delrin® acetal

100, 107, 100 P 500, 507 500 P, 900 P 100ST, 100T, 500T 500 CL 500 AF, 570

550 550 550 550

550 550 550 550

550 550 550 550 550 600

Rynite® PET

520 530

650

650

750

650

750

750

960

545 FR530 L FR 543 NC-010, FR 943 NC-010 RE 5211 S RE 5213 S 9082 F Zytel® PA66 unreinforced

E101 L 101 F E103 HSL 105 F BK-10 114 L BK-97 135 F 408 450 490 XA480 ST801

Zytel®

PA66 glass reinforced, flame retardant

FR70G25 V0 FR70G28 V1

6

6,4 mm

960 750 750 850 960 960 960 (0,8 mm) (2,2 mm) (3,2 mm) 960 750 (3,2 mm) 750 (0,8 mm) 850 960 960 (0,8 mm) 850 (1,6 mm) 750 850 960* 650 850 650* 675* 700* 750

960

960

960 960 960* 650 850 650* 650* 700*

960 960 960* 650 960 650* 650* 700* 650

850 (1,6 mm) 960

960

960 (1,2 mm)

960

650

1 mm Zytel® PA66 glass reinforced

2 mm

3 mm

650* 650 650* 700

650 (2,5 mm) 750 750 750* 850

79G13 L 70G20 HSL 70G25 HSL 70G30 HSL 70G60 HSL BK**

Zytel® PA66 glass-bead reinforced

70GB40 HSL


FR70M30 V0

Minlon® PA66 mineral reinforced

10B140

650* 650 650* 700

960 (at 1,2, 1,5 and 2,5 mm) 960 (at 1,2 mm) 750 (3,2 mm) 650 (3,1 mm)

11C140 Zytel® PA66/6 unreinforced, flame retardant

FR7200 V0F

960 (at 0,8, 1,6 and 3,2 mm)


FR72G25 V1

960 (1,5 mm)

FR72G25 V0

960 (1,6 and 3,2 mm)


7300, 7335 F

800 (1,6 mm)


73G15 73G30 HSL BK 73G40, 73G50

700

Zytel® PA6 mineral and glass reinforced, flame retardant, halogen and phosphorus free

FR73GM60 V0F, FR73GM60E V0F

960

FR73GM50 GWF

960

Zytel® HTN


750 750 960


4056

775


6130 WT-010, 7130 WT-010 6330 NC-010

960 960


SP-1, SP-21

high temperature nylon

* DuPont Laboratory test results.

** Only available in black.

6,4 mm

850

700

700

750

750

*** Only available in natural colour

For products or grades that do not appear on this table, please contact your DuPont representative for more information.

All the above information is subject to the disclaimer on the back page of this brochure.

7

Deflection temperature under flexural load, ASTM D 648, DIN 53461, ISO 75 °C

8

0,45 MPa DAM

1,8 MPa DAM

Crastin® PBT

S600, S620 ST820 SK601 SK603 SK605 SK609 LW9130 LW9020 LW9030 T805 SO653 SO655 HTI619 S650 FR S680 FR T850 FR SK642 FR SK643 FR SK645 FR CE7931 SK673 GW LW9020 FR LW9030 FR T841 FR T843 FR T845 FR HTI681 FR HTI668 FR HTI688 FR

160 105 215 220 220 222 202 215 215 205 185 212 220 160 175 167 218 220 220 221 220 215 220 200 204 205 194 200 205

60 48 185 204 205 215 180 172 182 190 70 99 200 65 64 60 203 205 210 210 205 175 190 183 188 192 88 185 190

Delrin® acetal

100, 107, 500, 507 100 ST 500T 500 CL 500 AF 570

170 145 165 170 168 174

115 70 90 105 105 158

Rynite® PET

520 530 545 555 935 FR515 FR530 L, FR543 FR943 RE5211 S RE5213 S 9082 F

251

220 224 226 229 200 200 224 220 227 203 232

0,45 MPa DAM

1,8 MPa DAM

235 240 235 240 230 225 219

80 90 77 88 69 65 66


E101 L, 101 F, E103 HSL 105 F BK-10 114 L BK-97 135 F 408 450, 490 ST801

Zytel® PA66 glass reinforced, flame retardant

FR70G28 V1 FR70G25 V0

243 244


79G13 L 70G20 HSL, 70G25 HSL 70G30 HSL, 70G35 HSL

242 254 254


FR70M30 V0

238

203


10B140 11C140

240 220

210 147

Zytel® PA66/6 unreinforced, flame retardant

FR7200 V0F


FR72G25 V1 FR72G25 V0


72G15 L 72G30 L 72G40 HSL BK*

Zytel® PA6 mineral and glass reinforced, flame retardant

FR73GM50 GWF

–

200


HTN 51G35 HSL HTN 51G45 HSL HTN FR51G35 L

276 276 270

264 264 255


7246

130

52


6130 WT-010 7130 WT-010 6330 WT-010

277 – –

265 295 245


SP-1, SP-21

75 240

226 215 215 222 224

360

* Only available in black. For products or grades that do not appear on this table, please contact your DuPont representative for more information. All the above information is subject to the disclaimer on the back page of this brochure.

9

Thermal Index - UL 746B measured at 0,8 mm Electrical

Mechanical with impact ºC

Mechanical without impact ºC

Crastin® PBT

S600, S620 SK601 SK603 SK605 SK609 LW9130 LW9020 LW9030 T805 SO653 SO655 HTI619 S650 FR SK642 FR SK643 FR SK645 FR CE7931 LW9020 FR LW9030 FR T841 FR T843 FR T845 FR HTI681 FR HTI668 FR HTI688 FR

130 130 130 130 130 140 130 130 130 120 120 130 130 140 140 140 130 140 140 130 130 140 140 125 125

115 115 130 130 125 125 125 125 130 115 120 125 130 130 130 125 130 115 125 120 120 130 130 125 125

120 120 130 130 130 140 130 130 130 120 120 130 130 140 140 140 140 120 130 130 130 140 140 125 130

Delrin® acetal

100*, 107*, 500*, 507* 100 ST* 500T* 500 CL* 500 AF* 570*

50 50 50 50 50 50

50 50 50 50 50 50

50 50 50 50 50 50

Rynite® PET

520 530 545 555 935 FR515 FR530 L FR543, FR943 RE5211 S RE5213 S

140 140 140 140 140 140 150 155 140 75

140 140 140 140 140 140 150 155 140 75

140 140 140 140 140 140 150 155 140 75

10

Electrical

Mechanical with impact ºC

Mechanical without impact ºC


E101 L, 101 F E103 HSL 105F BK-10 135 F 450, 490 ST801

130 140 125 135 65 125

75 95 65 75 65 75

85 115 65 85 65 85


79G13 L 70G20 HSL, 70G25 HSL 70G30 HSL, 70G35 HSL

105 105 140

65 65 125

105 105 140

FR70M30 V0

105

95

105

FR7200 V0F

130

105

130

Zytel® PA66/6 glass reinforced, FR72G25 V1 flame retardant FR72G25 V0

115 140

95 120

95 140

Zytel® PA66/6 glass reinforced 72G30 L

105

65

105


73M30

65

65

65


HTN 51G35 HSL HTN 51G45 HSL HTN FR51G35 L

150 150 140

125 125 120

130 130 130

240 210 130

240 240 130

Zytel® PA66 mineral reinforced, flame retardant Zytel® PA66/6 unreinforced, flame retardant

Hytrel® thermoplastic polyester 5556 elastomer

85

Zenite® LCD liquid crystal Polymer (1,5mm)

240 240 130

6130 WT-010 7130 WT-010 6330 WT-010

All the above information is subject to the disclaimer on the back page of this brochure. * All Delrin® grades are measured at 1,5 mm.

11

For further information on Engineering Polymers contact: Belgique / België Du Pont de Nemours (Belgium) Antoon Spinoystraat 6 B-2800 Mechelen Tel. (15) 44 14 11 Telex 22 554 Telefax (15) 44 14 09 Bulgaria Du Pont Bulgaria 18, Tcherni Vrah Blvd. Bldg. 2, Floor 5 BG-1407 Sofia Tel. (2) 66 59 13 / 66 57 36 Telex 24 261 DUPONT BG Telefax (2) 65 63 29/66 56 11 ˘ eská Republika a C Slovenská Republika Du Pont Conoco SA, s.r.o. Pekarska 14/628 CZ-155 00 Praha 5 Tel. (02) 574 14 111 Telefax (02) 574 14 250 Danmark DuPont Danmark A / S Roskildevej 163 Post boks 139 DK-2620 Albertslund Tel. +45 43 62 36 00 Telefax +45 43 62 36 17 Deutschland Du Pont de Nemours (Deutschland) GmbH DuPont Straße 1 D-61343 Bad Homburg Tel. (06172) 87 0 Telex 410 676 DPD D Telefax (06172) 87 27 01 Egypt Medgenco International Trade Co. 13, El Bostan Street ET-Cairo Tel. (02) 392 78 66 Telex 93 742 MK UN Telefax (02) 392 84 87 España Du Pont Ibérica S. A. Edificio L’Illa Avda. Diagonal 561 E-08029 Barcelona Tel. (3) 227 60 00 Telefax (3) 227 62 00 France Du Pont de Nemours (France) S.A. 137, rue de l’Université F-75334 Paris Cedex 07 Tel. 01 45 50 65 50 Telex 206 772 dupon Telefax 01 47 53 09 67

Start with DuPont Engineering Polymers 12/98 H-11740 part II

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Hellas Du Pont Agro Hellas S.A. 12, Solomou & Vas. Georgiou Street GR-152 32 Halandri, Athina Tel. (01) 680 16 14 Telefax (01) 680 16 11 Israël Gadot Chemical Terminals (1985) Ltd. 22, Shalom Aleichem Street IL-633 43 Tel Aviv Tel. (3) 528 62 62 Telex 33 744 GADOT IL Telefax (3) 282 717 Italia Du Pont de Nemours Italiana S.p.A. Via Aosta 8 I-20063 Cernusco sul Naviglio (Mi) Tel. (02) 25 302.1 Telefax (02) 92 107 845 Magyarország Serviced by Interowa. See under Österreich. Maroc Deborel Maroc S. A. 40, boulevard d’Anfa - 10 o MA-Casablanca Tel. (2) 27 48 75 Telex 23 719 BOUKBEN Telefax (2) 26 54 34 Norge Distrupol Nordic Niels Leuchsvei 99 N-1343 Eiksmarka Tel. 67 14 10 00 Telefax 67 14 02 20 Österreich Interowa Fürer-Haimendorf KG Bräuhausgasse 3-5 A-1050 Wien Tel. (01) 512 35 71 Telex 112 993 IROWA A Telefax (01) 512 35 71 12 / 512 35 71 31 Polska Du Pont Conoco Poland Sp.z o.o. ul. Prosta 69 PL-00-838 Warszawa Tel. (22) 635 04 01 Telefax (22) 691 09 00 Portugal ACENYL Rua do Campo Alegre, 672 - 1o P-4100 Porto Tel. (2) 69 24 25 / 69 26 64 Telex 23 136 MACOL Telefax (2) 600 02 07

Romania Serviced by Interowa. See under Österreich. Russia E. I. du Pont de Nemours & Co. Inc. Representative Office B. Palashevsky Pereulok 13 / 2 SU-103 104 Moskva Tel. (095) 797 22 00 Telex 413 778 DUMOS SU Telefax (095) 797 22 01 Schweiz / Suisse / Svizzera Dolder AG Immengasse 9 Postfach 14695 CH-4004 Basel Tel. (061) 326 66 00 Telex 962 306 DOL CH Telefax (061) 326 62 04 Slovenija Serviced by Interowa. See under Österreich. Suomi / Finland Du Pont Suomi Oy PL 199 FIN-02201 Espoo Tel. 09-725 66 100 Telefax 09-725 66 166

United Kingdom Du Pont (U.K.) Limited Maylands Avenue GB-Hemel Hempstead Herts. HP2 7DP Tel. (01442) 34 65 00 Telefax (01442) 24 94 63 Argentina Du Pont Argentina S.A. Avda. Mitre y Calle 5 (1884) Berazategui-Bs.As. Tel. (541) 319-4484 / 85 / 86 Telefax (541) 319-4417 Brasil Du Pont do Brasil S.A. Al. Itapecuru, 506 Alphaville 06454-080 Barueri-São Pãolo Tel. (5511) 421-8468 / 8556 Asia Pacific Du Pont Kabushiki Kaisha Arco Tower, 14th Fl. 8-1, Shimomeguro 1-chome Meguro-ku, Tokyo 153 Tel. (03) 5424 6100 South Africa Plastamid P.O. Box 59 Elsies River 59 Cape Town Tel. 27 (21) 592 12 00 Telefax 27 (21) 592 14 09

Sverige DuPont Sverige AB Box 23 S-164 93 Kista (Stockholm) Tel. +46 8-750 40 20 Telefax +46 8-750 97 97

USA DuPont Engineering Polymers Barley Mill Plaza, Building #22 P.O. Box 80022 Wilmington, Delaware 19880 Tel. (302) 892 0541 Telefax (302) 892 0737

Türkiye Du Pont Products S.A. Turkish Branch Office Sakir Kesebir cad. Plaza 4 No 36 / 7, Balmumcu TR-80700 Istanbul Tel. (212) 275 33 83 Telex 26541 DPIS TR Telefax (212) 211 66 38

Requests for further information from countries not listed above should be sent to:

Ukraine Du Pont de Nemours International S.A. Representative Office 3, Glazunova Street Kyiv 252042 Tel. (044) 294 9633 / 269 1302 Telefax (044) 269 1181

Du Pont de Nemours International S.A. 2, chemin du Pavillon CH-1218 Le Grand-Saconnex Geneva Tel. (022) 717 51 11 Telex 415 777 DUP CH Telefax (022) 717 52 00 Internet location: http://www.dupont.com/ enggpolymers/europe

The information provided in this documentation corresponds to our knowledge on the subject at the date of its publication. This information may be subject to revision as new knowledge and experience becomes available. The data provided fall within the normal range of product properties and relate only to the specific material designated; these data may not be valid for such material used in combination with any other materials or additives or in any process, unless expressly indicated otherwise. The data provided should not be used to establish specification limits nor used alone as the basis of design; they are not intended to substitute for any testing you may need to conduct to determine for yourself the suitability of a specific material for your particular purposes. Since DuPont cannot anticipate all variations in actual enduse conditions DuPont makes no warranties and assumes no liability in connection with any use of this information. Nothing in this publication is to be considered as a license to operate under or a recommendation to infringe any patent rights. Caution: Do not use this product in medical applications involving permanent implantation in the human body. For other medical applications see “DuPont Medical Caution Statement ”, H-50102.

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