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Du Pont Engineering Polymers : 05 September, 2003  (Company News)
Epcos AG chose DuPont
Epcos, a major developer and manufacturer of leading-edge electronic components, chose this liquid crystal polymer for its optimal combination of properties, which include high dielectric strength and thermal resistance, and very good melt-flow. These characteristics are essential for making miniaturised electronic components for mounting on circuit boards with SMD technology.

The growing use of digital subscriber line (DSL) technology, which is expected to increase further with video-on-demand, teleworking and telelearning, requires an increased bandwidth for signal transmission between Internet service providers’ central offices and customer premises. Epcos’ specially developed EPX and EPO core geometries, made of T66 and T57 ferrite materials, offer good data transmission rates combined with greater miniaturisation.

For making the coil formers for these applications, Epcos, based in Munich, uses Zenite® 7130. This glass-fibre-reinforced LCP combines good toughness with a heat deflection temperature of 289 °C and high dimensional stability. Containing no halogen additives, the material is recognised by Underwriters Laboratories as UL 94 V-O at 0.75 mm. Processing this LCP is less costly than working with thermosetting resins, because the melt sets rapidly and injection-moulded parts of Zenite® do not need to be de-flashed. LCPs in general are highly suitable for the cost-efficient manufacture of many electrical and electronic components for the automotive, telecommunications and aerospace industries.

Josef Sedlmeier, Ferrite Components project leader at Epcos, comments: “Thanks to the good melt-flow properties of Zenite®, we can injection-mould very fine coil formers with a wall thickness of less than 0.4 mm and a footprint of 25 mm2. With the high strength and impact resistance of this LCP, these precision parts are nevertheless robust enough to withstand the stresses that occur during coil-winding. The high thermal deflection temperature of Zenite® 7130 means that parts can withstand temperature peaks of up to 260 °C, which occur during reflow-soldering, when the complete transformers are mounted on the circuit board.”

“Our new ferrites allow SMD transformers to be miniaturised without compromising their performance,” Sedlmeier continues. “This means, for example, that more ADSL interface transformers can be mounted per unit of PCB real estate; this in turn helps to lower per-connection costs at the switching centre.”

Epcos’ EP range of SMD transformers, designed for an operating voltage of 250 V (test voltage 1 500 V) meet international standards for telecommunications applications, such as EN 60950, IEC 950, UL 1950/CSA 950 and AS/NZS 3260. Typical applications for these ferrite transformers are high-pass and low-pass filters, impedance matching and electrical insulation transformers.
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