Delphi Automotive Systems, a leading Tier One supplier of electronics and technologies to the automotive industry, has approved DSM’s Stanyl TW200F6 for the Ignition Connector soldered onto the Ignition Coil specified by an OEM for 4 and 6 cylinder engines.
The ignition connector is produced by Delphi Portugal where the terminals are overmolded using a rotating mold. Stanyl TW200F6 is also used for a latch being part of the ignition coil assembly. These components are shipped to Delphi Portugal and combined with the ignition connector for final assembly. The terminals are protected by potting with epoxy after plasma pre-treatment of Stanyl. The Ignition Coil supplies the required electrical voltage and energy needed to ignite air-fuel mixtures in the engine's combustion chamber.
Stanyl was specified by the OEM because of its high temperature resistance, excellent mechanical performance, and wave soldering capabilities. Key processing benefits include low viscosity, fast cycle time, ability to mold in high cavitations tools, mechanical property performance at elevated temperature, excellent mechanical performance (balance of mechanical properties and flow), and wave soldering capabilities.
Compared with PA66, Stanyl TW200F6 delivers better melt flow and mechanical properties, which allow the material to flow around sensor elements and inserts for better sealing and encapsulation, improved surface quality, and longer product life. In addition, the superior melt flow lessens the potential for damage to sensor elements and wires as it reduces injection moulding cycle times and tooling wear.
Stanyl TW200F6 components provide superior resistance to transmission fluids and engine oils and give an extra margin of stiffness to handle fluid pressures. Its resin-rich surface seals better than alternatives to sensors and inserts.
Delphi says: “Stanyl’s combination of high temperature resistance, excellent mechanical performance, and wave soldering capabilities make it an excellent product for this specific application, as well as for other automotive electronics”.
Higher crystallinity and a faster rate of crystallization give Stanyl a technical edge over such engineering plastics as PA6, PA66, polyesters, and other high heat-resistant resins such as semi-aromatic polyamides (PPAs), PPS and LCPs. Compared to these, Stanyl grades show better heat resistance, mechanical properties at elevated temperatures, wear and friction behavior and, with faster cycle time and increased flowability, improved processing economics.
According to Greg Costantino, Global Segment Manager - Automotive Electronics at DSM, the use of Stanyl TW200F6 is a clear example of the application of DSM’s Brighter Science: “Manufacturers are increasingly turning to advanced performance materials capable of reducing weight to minimize CO2 emissions. Stanyl enables manufacturers to reduce the carbon footprint over the life cycle of their vehicles, help preserve scarce raw materials and meet future regulation on greater re-use and recovery of materials at the end of a vehicle’s life, while at the same time helping end users reduce fuel consumption. Moreover, Stanyl can be molded at lower pressures and faster cycle time than other polyamide based materials. This results in energy savings during the molding process.”
Stanyl TW200F6 is one of the Stanyl family of heat-resistant polyamide moulding compounds, produced and marketed exclusively by DSM and available worldwide. Stanyl is used in demanding applications in the automotive and electrical and electronics industries, as well as many other applications. Stanyl is offered in a wide variety of grades including high-flow, abrasion-resistant, and unfilled (non-reinforced), as well as grades containing glass fibres, minerals, lubricants, impact modifiers or flame retardants.
Stanyl delivers performance for ignition coil connectors