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News

Rynite PET stands up to heat in New Ford Electric Car

Du Pont Engineering Polymers : 02 January, 2002  (New Product)
A large transformer bobbin made of DuPont Rynite PET thermoplastic polyester resin plays a key role in recharging the battery of Ford Motor Company's new 'Th!nk' electric-powered vehicle. The transformer bobbin is part of the Th!nk's sophisticated built-in battery charger developed by Diversified Power International, LLC. Plugged into an ordinary house-current outlet, the charger steps down the main power supply to 72 volts and converts alternating current to direct current for the battery. During charging, the bobbin made of Rynite PET withstands a temperature rise of 100
A large transformer bobbin made of DuPont Rynite PET thermoplastic polyester resin plays a key role in recharging the battery of Ford Motor Company's new 'Th!nk' electric-powered vehicle.

The transformer bobbin is part of the Th!nk's sophisticated built-in battery charger developed by Diversified Power International, LLC. Plugged into an ordinary house-current outlet, the charger steps down the main power supply to 72 volts and converts alternating current to direct current for the battery.

During charging, the bobbin made of Rynite PET withstands a temperature rise of 100C (212F) above ambient temperature. Ford's ambient temperature specification runs from -20C to +50C (-4F to 122F).

As bobbins go, the charger part is relatively large. It measures 5.5 in. high by 4.25 inches wide (140 by 108 mm). The bobbin holds both primary and secondary windings, which are separated by an insulating flange. The finished coil is placed in a water-tight cast aluminum housing.

'Rynite provides strength, heat-resistance, easy molding and other required characteristics for the bobbin,' says Ken Muszynski, president of Foremost Plastics, Inc., Elmwood Park, Ill. His company molds the bobbin from Rynite FR530L, a lubricated, flame-retardant grade with 30 percent glass reinforcement. 'The resin has excellent flow characteristics to fill large mold cavities without creating voids,' says Muszynski. 'It also sets up quickly and releases easily from the mold to optimize cycle time and improve yields.'

Battery charger manufacturer Diversified Power International also credits Rynite for helping speed the component's development time. 'Rynite is part of a pre-approved DuPont Electrical Insulation System, and that meant a lot less UL testing and data submission for us, so it saved us both time and expense,' says Jerry Fagan, the firm's president. The system meets Class H (180C) requirements ) under UL 1446 and IEC 62114 standards.

DPI's charger is a five-stage device with intelligent circuitry that automatically recharges the battery if the vehicle has not been been used for 28 days. 'That's a great benefit to people who have to leave their vehicles unattended for a time, such as retirees who are away for months,' says Fagan, 'because they can expect a fully functional battery upon their return.' Before charging, the unit also tests to assure that the battery is still charge-capable.

The Th!nk electric vehicle, manufactured by Ford's Th!nk Mobility Group, will be sold through Ford dealers in selected markets in the U.S. starting this year. In 1999, it made its debut in Norway and has since become popular throughout Scandinavia.

To learn more about the bobbin manufacturing capabilities of Foremost Plastics, call 708-452-5300 or visit www.foremostplastic.com

To learn more about Diversified Power International's battery chargers, call 423-538-9002, or visit www.dpichargers.com
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