On display by DuPont at NPE! Booth 2632, South Hall

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. The new resin, Thermx® TE4001, is making its debut at the NPE 2006 plastics exhibition this week.

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 200ºC. Its maximum operating temperature in ignition coils is 170ºC.

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® TE4001 does 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 130ºC. For requirements up to 150ºC, DuPont™ Rynite® PET polyester can fill the bill. And Thermx® PCT can go on up to 170ºC.

DuPont is a science company. Founded in 1802, DuPont puts science to work by creating sustainable solutions essential to a better, safer, healthier life for people everywhere. Operating in more than 70 countries, DuPont offers a wide range of innovative products and services for markets including agriculture, nutrition, electronics, communications, safety and protection, home and construction, transportation and apparel.

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6/20/06

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