Forum for Science, Industry and Business

Sponsored by:     3M 
Search our Site:

 

Primerless bonding of DuPont™ Zytel® nylon and DuPont™ Vamac® AEM for integrated electronic connector gasket

18.10.2011
A new electronic connector gasket from Dana Corporation of Neu-Ulm, Germany, is one of the first applications to benefit from patented 2K molding technology for the production of assemblies combining DuPont™ Vamac® ethylene acrylic elastomer (AEM) with DuPont™ Zytel® nylon resin.

The multi-shot technology, licensed solely to DuPont by Evonik Degussa GmbH, allows the direct bonding of rubber and plastics and simplifies assembly by eliminating the need for primer or anchoring. The upshot of the new technology for first tier suppliers of integrated automotive components, such as Dana Corporation, is the opportunity for greater cost and processing efficiencies as well as enhanced part quality and reliability, even after heat and automotive fluid aging.


Photo: Courtesy of DANA corporation
A new electronic connector gasket from Dana integrates wiring harness, power connectors and DuPont™ Zytel® and Vamac® polymers in a primerless bond, reducing assembly time by 30-40% and component cost by 25-40% compared with conventional gaskets and separate wiring harnesses.


Photo: Courtesy of DANA corporation
This detail of the new Dana integrated electronic connector gasket shows elastomeric sealing surfaces of Vamac® AEM (shown in blue) bonded permanently to rigid structural parts of Zytel® PA66 nylon resin (shown in black) to provide oil and high temperature resistance, while eliminating leak paths.

In the case of the highly integrated connector gasket, which includes both a wiring harness and power connectors, its seal made of Vamac® AEM is permanently bonded to the gasket body of Zytel® nylon to provide long term heat and oil resistance and to eliminate leakages. The particular grade of Zytel® nylon 6,6 specified for the gasket body combines excellent mechanical properties with enhanced heat aging performance, hydrolysis resistance and improved oil resistance. For its part, when used in seals, Vamac® AEM provides high sealing performance, low permeability and excellent resistance to oil and grease. Moreover, seals made of Vamac® AEM are highly resistant to compression set and maintains long-term sealing force, meaning that the gasket can be disassembled and reassembled again for reuse.

“The greatest challenge was to seal metals, thermoplastics and rubber materials at the open window connector point. We worked closely with DuPont to modify the polymers and develop new process technology to create optimal adhesion between Zytel® nylon and Vamac® AEM throughout the gasket,” comments Berthold Schiele, sales engineer and project manager for plastic systems at Dana. “The adhesion of Vamac® AEM to Zytel® nylon exceeded our expectations. We subjected the bonded materials to a special pull force test, but the extra force necessary to separate the two far exceeded the actual operating conditions the gasket will meet in long-term service. Consequently, we can see considerable potential application for this technology and materials combination in the future.”

The Dana gasket is the first to integrate wiring harness, all fuel injector, plug, sensor and actuator/solenoid power connections. The result is a highly-integrated unit, complete with pre-assembled wiring harness that can reduce assembly time by 30-40%, and eliminates the need to machine cylinder head holes, feed cables or control wiring direction. Thus, accurate positioning of all power connections is assured, while yielding a 25-40% component cost saving compared with conventional gaskets and separate wiring harnesses.

In addition to undergoing a 150,000 mile in-vehicle endurance trial, the electronic connector gasket has met or exceeded all industry standard tests, including heat aging, and exposure to internal engine heat, oil and dynamic operating conditions. Its subsequent adoption by major players in the off-highway, construction, agricultural, stationary and marine diesel engine markets has been rapid. The first commercial installations in Europe took place from early 2010 in large diesel engines manufactured by MTU, Deutz, and Liebherr, following exhaustive validation and field trials.

DuPont Performance Polymers is committed to working with customers throughout the world to develop new products, components and systems that help reduce dependence on fossil fuels and protect people and the environment. With more than 40 manufacturing, development and research centers throughout the world, DuPont Performance Polymers uses the industry’s broadest portfolio of plastics, elastomers, renewably sourced polymers, filaments and high-performance parts and shapes to deliver cost-effective solutions to customers in aerospace, automotive, consumer, electrical, electronic, industrial, sporting goods and other diversified industries.

DuPont (NYSE: DD) has been bringing world-class science and engineering to the global marketplace in the form of innovative products, materials, and services since 1802. The company believes that by collaborating with customers, governments, NGOs, and thought leaders we can help find solutions to such global challenges as providing enough healthy food for people everywhere, decreasing dependence on fossil fuels, and protecting life and the environment. For additional information about DuPont and its commitment to inclusive innovation, please visit www.dupont.com.

The DuPont Oval Logo, DuPont™, The miracles of science™ and all product names denoted with a ® are registered trademarks or trademarks of E.I. du Pont de Nemours and Company or its affiliates.

PP-Fakuma-2011-19 Press contact (UK, Benelux, Scandinavia)

Andrew Wilkins
Tel.: +44 (0)1353 663350
Fax: +44 (0)1353 663350
Email: dupont@plasticspr.co.uk
DuPont press contact
Rémi Daneyrole
Tel.: +41 (0)22 717 54 19
Fax: +41 (0)22 580 22 45

Ursula Herrmann | Konsens Public Relations
Further information:
http://www.dupont.com

More articles from Trade Fair News:

nachricht The Micro Nanotech area at MD&M West has been successfully established
22.02.2017 | IVAM Fachverband für Mikrotechnik

nachricht Use your Voice – and Smart Homes will “LISTEN”
21.02.2017 | EML European Media Laboratory GmbH

All articles from Trade Fair News >>>

The most recent press releases about innovation >>>

Die letzten 5 Focus-News des innovations-reports im Überblick:

Im Focus: Breakthrough with a chain of gold atoms

In the field of nanoscience, an international team of physicists with participants from Konstanz has achieved a breakthrough in understanding heat transport

In the field of nanoscience, an international team of physicists with participants from Konstanz has achieved a breakthrough in understanding heat transport

Im Focus: DNA repair: a new letter in the cell alphabet

Results reveal how discoveries may be hidden in scientific “blind spots”

Cells need to repair damaged DNA in our genes to prevent the development of cancer and other diseases. Our cells therefore activate and send “repair-proteins”...

Im Focus: Dresdner scientists print tomorrow’s world

The Fraunhofer IWS Dresden and Technische Universität Dresden inaugurated their jointly operated Center for Additive Manufacturing Dresden (AMCD) with a festive ceremony on February 7, 2017. Scientists from various disciplines perform research on materials, additive manufacturing processes and innovative technologies, which build up components in a layer by layer process. This technology opens up new horizons for component design and combinations of functions. For example during fabrication, electrical conductors and sensors are already able to be additively manufactured into components. They provide information about stress conditions of a product during operation.

The 3D-printing technology, or additive manufacturing as it is often called, has long made the step out of scientific research laboratories into industrial...

Im Focus: Mimicking nature's cellular architectures via 3-D printing

Research offers new level of control over the structure of 3-D printed materials

Nature does amazing things with limited design materials. Grass, for example, can support its own weight, resist strong wind loads, and recover after being...

Im Focus: Three Magnetic States for Each Hole

Nanometer-scale magnetic perforated grids could create new possibilities for computing. Together with international colleagues, scientists from the Helmholtz Zentrum Dresden-Rossendorf (HZDR) have shown how a cobalt grid can be reliably programmed at room temperature. In addition they discovered that for every hole ("antidot") three magnetic states can be configured. The results have been published in the journal "Scientific Reports".

Physicist Dr. Rantej Bali from the HZDR, together with scientists from Singapore and Australia, designed a special grid structure in a thin layer of cobalt in...

All Focus news of the innovation-report >>>

Anzeige

Anzeige

Event News

Booth and panel discussion – The Lindau Nobel Laureate Meetings at the AAAS 2017 Annual Meeting

13.02.2017 | Event News

Complex Loading versus Hidden Reserves

10.02.2017 | Event News

International Conference on Crystal Growth in Freiburg

09.02.2017 | Event News

 
Latest News

Microhotplates for a smart gas sensor

22.02.2017 | Power and Electrical Engineering

Scientists unlock ability to generate new sensory hair cells

22.02.2017 | Life Sciences

Prediction: More gas-giants will be found orbiting Sun-like stars

22.02.2017 | Physics and Astronomy

VideoLinks
B2B-VideoLinks
More VideoLinks >>>