ENGINEERING THERMOPLASTICS | MATERIALS
Foldable and renewable
Several models of foldable phones feature structural parts moulded from new, renewably sourced Zytel PA610 grades from DuPont Mobility & Materials: Zytel FE150065 BK010 and Zytel RS32G10DO BK236. Typical application is the mainboard cover. The supplier says Zytel RS32G10DO BK236 is formulated for low density and balanced stiffness/toughness along with excellent dimensional stability. It can reduce part weight by 30% or more when compared to the incumbent structural materials. In one foldable smartphone application, a manufacturer replaced polycarbon-
ate for the PCB board cover with Zytel FE150065 BK010. This switch removes 0.5g from the part weight with even higher stiffness than polycarbonate. It also lowers the GWP (global warming potential) for the entire device.
There will be a family of solutions, tailored to
different frequencies (around 4,000-5,000 Hz) and different operating temperatures. DuPont Mobility & Materials has reported a similar development to Ascend, with its newly formulated PA66-based compound, Zytel NVH Gen 2. Its automotive electrification team developed Zytel NVH70G35HSLA2, the first entry in the Zytel NVH Gen 2 product family. This 35% glass-filled product is said to offer high damping, yet keeps its base polymer’s robust structural properties for parts that need sustained mechanical strength throughout their lifecycles. According to Gabe Knee, Automotive Market
Manager, the new grade takes a different approach to high-frequency vibration isolation by utilising the material’s structural damping ability without sacrificing extended fatigue resistance over time. The material can endure high-stress conditions and provide stable characteristics under varying ambient and loading conditions. In a recent commercial application in North America involving EV motor mounts, Zytel NVH Gen 2 maintained structural integrity while offering over 20% direct mass savings and considerable material cost savings compared to aluminium. Ascend is also looking for materials to handle higher voltages in EVs, so that they can charge more quickly. DuPont Mobility & Materials showed a new hybrid plastic/metal cooling plate it is co-develop- ing with automotive Tier 1 Novares that they say will help OEMs extend the range and lifetime of their EV batteries. One key to this new project is the patented plastic/metal bonding technology developed at DuPont’s technology centre in Meyrin, Switzerland. According to Laurent Vanhol- me, Expert Powertrain Components at Novares: “We were able to master the difference in thermal
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expansion between the metal and plastic parts, and re-engineer the product to be processed with conventional welding.” “When it comes to the flame-retardant plastics
that make up many EV components, designers must ensure that the materials they specify retain mechanical properties, process easily, deliver dimensional stability for big and flat parts, enable design flexibility, and withstand a wide temperature range,” says the company. It has developed new halogen-free flame-retardant material grades aimed at overcoming limitations in all of these categories. Solutions include compounds based on PAs, PPA, and PBT. For example, Zytel FR70G30V0NH2 (PA66- based) is said to deliver exceptional mechanical properties, low mould deposit, easy processing and laser transparency for laser welding, while Zytel HTN FR53G50NH and Zytel HTN FR53G30NH2 (PPA-based) provide very good mechanicals for structural parts. Crastin LW- FR864NH2 (PBT-based), with high dimensional stability, is for long, thin parts common in EV
Below: DuPont Mobility & Materials has developed halogen-free flame-retardant PA, PPA and PBT grades
November/December 2022 | INJECTION WORLD 31
IMAGE: DUPONT
IMAGE: DUPONT
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