Case Study: Coil Encapsulated in Zytel® is Key Component in Air Conditioner Clutch
Encapsulation with DuPont™ Zytel® nylon resin replaces bobbin-wound coils and extends thermal cycling performance.
Application Description
A coil encapsulated in Zytel® nylon resin is a key component of Warner Electric's World Clutch™ for automotive air conditioners. When energized, the coil acts like a solenoid, causing the clutch to engage the compressor.
Materials Selected and Why
Zytel® based on 66 nylon with 33% glass reinforcement meets needs for:
- Excellent thermal cycling performance
- Resistance to oils, greases, automotive fluids
- Under-the-hood temperature resistance
- High productivity and quality in encapsulation injection molding
Benefits Gained
In replacing bobbin-wound, or potted epoxy coils with components encapsulated by injection molding, Warner achieved:
- Improved manufacturability of coils to 6-Sigma quality requirements
- Lower assembly costs
- Elimination of VOC (volatile organic compound) emissions
- Flexible manufacturing – Interchangeable mold inserts permit use of the same tool to encapsulate coils terminated with either leads or connectors
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