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News

Tyco new electronics molds connector in AMODEL AS-4133 HS Polyphthalamide

Solvay Advanced Polymers Llc : 03 October, 2003  (New Product)
Engineers at Tyco Electronics have chosen an AMODEL polyphthalamide material from Solvay Advanced Polymers, L.L.C. for a 190-pin header connector that is used in an automotive underhood application. The specific grade, AMODEL AS-4133 HS, is one of a series of heat stabilized, glass-reinforced resins that are designed to exhibit excellent strength and stiffness over a broad temperature range.
The connector is part of a power control module that is mounted in the automobile’s engine bay. There it controls and monitors engine settings, providing optimal performance and improving overall fuel efficiency. The ability of the AMODEL resin to maintain its dimensional stability with changes in temperature was a key consideration in material selection.

Resistance to high process temperature In order to meet USCAR Class 3 requirements, the connector must be capable of operating in ambient temperatures from −40°C to +125°C, with the ability to withstand a peak of +145°C.

The critical temperature driving the choice of this AMODEL resin, however, is not seen by the part during normal automotive operation, but is a much higher heat to which it is subjected during the assembly process. The connector is attached to the module’s circuit board by a process known as “IRreflow.” During the reflow process, the connector’s 190 pins are soldered to a printed circuit board at AMODEL chosen for connector in automotive underhood application a temperature of 250°C. The heat-deflection temperature of the connector’s material must be sufficient to withstand this heat without charring or melting. The part must also resist any distortion that might cause stresses in the circuit board. In addition to its temperature performance, the AMODEL material provides the chemical resistance required to withstand the fluids that are common to the engine-compartment environment.

The HDT value for AMODEL AS-4133 HS is measured at 300°C at 264 psi, which is higher than most conventional nylons that could be specified for this application. And this AMODEL grade is significantly less expensive than polyphenylene sulfide materials that are also used. Hot-water molding, shorter cycle times Tyco Electronics molds this header with 190 circuit holes in the part for insertion of the connector pins, which are inserted by a mechanical “stitching” operation. According to the Plastics Manufacturing Engineer at Tyco Electronics, the AMODEL material crystallizes quickly using conventional hot-water molding, resulting in faster cycle times compared to other resins in its class.
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