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News

Thin, hot-running ignition parts? DuPont Thermx PCT answers the call

Du Pont Engineering Polymers : 27 July, 2006  (Company News)
A new grade of DuPont Thermx PCT high-performance polyester has what it takes to make durable components for the emerging generation of smaller, hotter-running automotive ignition coils.
For coil-on-plug and pencil coil ignition systems installed close to the engine block, Thermx TE4001 delivers an outstanding combination of attributes required for production of rugged, dependable coil bobbins and housings. Its key attributes include excellent high-temperature electrical endurance, strength, toughness, thermal shock resistance, thin-wall molding capability, processing stability and epoxy adhesion.

Thermx TE4001 provides outstanding high-temperature electrical endurance. Its dielectric strength remains virtually constant in the 41 to 42 kV/mm range from ambient temperatures up to 200C. Its maximum operating temperature in ignition coils is 170C.

Owing to space constraints, coil-on-plug and pencil coil designs often use thinner, smaller coil forms. Thermx TE4001 meets this need with mold flow performance surpassing that of alternative high-temperature plastics such as modified polyphenylene oxide. The new resin also has improved thermal stability to withstand molding holdup events.

Toughness is another key attribute of Thermx TE400. Its elongation (strain at break) value is 3.7 percent. This is more than adequate for the design of parts that can resist breakage during assembly, handling and service, and it is substantially higher than that of other glass-reinforced grades of Thermx. The new TE4001 grade contains a combination of glass fiber and glass flake reinforcement.

The new resin also exhibits good adhesion to epoxy resins, which are used for coil encapsulation. This helps ensure the electrical integrity of encapsulated coils during service. Unlike some alternative resins, Thermx TE4001does not require costly plasma treatment.

Ignition coil manufacturers can find a continuum of material solutions in the DuPont portfolio of engineering plastics. DuPont Crastin PBT polyester performs well in coils operating up to 130C. For requirements up to 150C, DuPont Rynite PET polyester can fill the bill. And Thermx PCT can go on up to 170C.
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