®

DuPont Engineering Polymers

® DuPont registered trademark

Engineering Polymers
for electric motors
Front page:
– General purpose motor from FHP Elmotor AB
– Window lift motor from Meritor
Contents

Page
Introduction
- Worldwide motor manufacture
and DuPont's global team 4
- The total DuPont offering 5
- Traditional versus new approach 6-7
- Vespel® 8
- Automotive window lift motor 9
- Significant cost savings 10

Electrical insulation and

approved insulating systems
from DuPont
- UL 1446/IEC 85 Electrical Insulation Systems (EIS) 11
- Thermoplastic encapsulation 11
- Advantages of high temperature
insulation systems 12
- DuPont family of insulating materials 12

Motor design

- Rotors and stators 14

- Overmoulding 14
- Commutators 16
- End frames 16
- Stiffness, strength and creep resistance 18-19
- Bearings and bearing housings 20-22
- Gears and gear housings 22
- Brush holders 22
- Motor cooling fans 23
- Function integration 24
- Assembly features 25
- Frame extensions and housings 26
- Interconnects 26
- Motor design innovations 27
- Noise, vibration and harshness 28

3
DuPont's Global Motors Team can assist you
whenever and wherever you need it
Today's electric motor design teams are broad range of elastomers, films, equipment. Many of the examples used
being confronted by more challenges fabricated components, fibres, chemicals, are just re-thinking of an old concept,
than ever before. There is a particular refrigerants, advanced structural but in each case new materials have
need to develop more cost effective composites, electronic materials, met the needs of a designer, engineer
motors for an increasingly competitive and finishes. or end-user.
marketplace. As a result, a new and
broader range of engineering and insu- This brochure illustrates many of the For more information on DuPont's
lation materials is changing the way in advantages and options that result from family of engineering materials,
which motors are designed, manufac- incorporating DuPont's engineering contact your nearest DuPont office
tured and assembled. materials in your motor design. You (see back page for contact addresses).
will find ideas ranging from plastic
Global Motors Team bearings to extensions of thermoplastic
motor frames, rotor insulation, and
To help you take full advantage of protective devices used in motor control
the latest materials and technology
when you optimize an existing design
or develop a new motor, DuPont has
established a Worldwide Motors Team.
By drawing on its global experience
and resources, you are assured of proper
material selection, part design and
processing. The motors team can help
you:
• design motor components
• with material selection
• with processing support

Global technical support

DuPont has R&D, manufacturing,
technical service and distribution facili-
ties throughout the world. When you
purchase engineering materials for
electric motors, technical support is
part of the offering. You have opened
the door to a world of knowledge that
can provide you with valuable practical
help at every stage of your project.
The DuPont technical centres, located
in strategically selected regions around
the world, can provide you with
invaluable assistance. And DuPont will
work with you from concept through
to commercialization.
DuPont's global offering for
electric motors
State-of-the-art insulation technology
provides motor manufacturers greater
design flexibility and the opportunity
to reduce costs. DuPont offers you the
largest range of electrical insulation
systems, and each comes with a variety
of approvals by testing agencies, includ-
ing Underwriters' Laboratories, IEC
and CSA. What's more, engineering
polymers also provide many benefits
in housing, motor bracket and bearing
applications. These materials can
reduce finished part costs through
simplified assembly, parts integration,
and lower material costs.
Although this brochure concentrates on
engineering polymers used in electric
motors, DuPont's total offering goes far
beyond this. It includes an extremely

4
Engineering polymers
Crastin® PBT
thermoplastic polyester resin
Delrin®
acetal resin
Hytrel®
thermoplastic polyester elastomer
Minlon®
mineral reinforced nylon resin
Rynite® PET
thermoplastic polyester resin
Zenite® LCP
liquid crystal polymer
Zytel®
nylon resin
Zytel® HTN
high temperature nylon resin

Fluoropolymers
Teflon®
fluorocarbon resins
Tefzel®
fluorocarbon resins

Material for high

performance bearings
Vespel® polyimide
parts and shapes

Sheet structures for

electrical insulation
Nomex® brand sheet structures

Lubrication
Krytox®
fluorinated oil and grease

Films for electrical

insulation
Mylar®
polyester film
Kapton®
polyimide film

Wire & cable materials

Elvaloy®
Hytrel®
thermoplastic polyester resin
Kapton®
polyimide film
Teflon®
fluorocarbon resins
Tefzel®
fluoropolymer

®
DuPont's registered trademarks.

5
Traditional universal motor construction

The majority of motors produced today

are still manufactured using large
numbers of components in traditional
materials such as paper or films for
insulation, thermosets for brush holders,
and die-cast metals for end frames.
A significant proportion of the cost of
the finished motor results from labour-
intensive assembly.

Tacho-generator (or encoder) screwed

to die-cast end frame

Brush holder mouldings

Fixing screws for connector

Separate connector
mounting plate

De-flashed and machined die-cast

end frame

Paper/tape insulation for stator

windings Separate connector
moulding

Field coils secured to

laminations by pins or clamps

Individual paper or film slot

insulators

Paper or film end insulators

End frame in metal or thermoset

6
Design utilizing the features of engineering polymers

DuPont engineering polymers offer a • Parts integration and reduced • Efficient, reliable wire winding
better, more cost effective solution. assembly costs • Free UL and IEC recognition for
High performance polymers, including • Close part tolerances materials and insulation systems up
Rynite® glass reinforced PET polyester, as • Stiffness and dimensional stability to Class R
well as Zytel® nylon, Zytel® HTN high • Reliable performance at high • No finishing or machining normally
temperature nylon, Crastin® PBT, temperatures necessary
Zenite® LCP and Minlon® mineral
reinforced nylon, Hytrel® thermoplastic
polyester elastomer and Vespel® poly-
imide parts facilitate parts integration.
In addition, they provide superior
thermal properties, thin-walled stiffness,
processibility and:

Snap-fits for tacho-generator

(or encoder)

Integrated push-fit brush holder

End frame moulded in Rynite® PET,
Crastin® PBT, Zytel®, Zytel® HTN with
integral brush holders and integral
connector

Vespel® thrust plug (see next page)

Overmoulding acting as both coil
former and stator insulation

High performance lead wire

insulation (e.g. Kapton® or Tefzel®)

Overmoulded rotor insulation.

The insulation of slots, ends and
shaft provides double insulation
Hytrel® overmoulding to reduce
noise and vibration

End frame moulded in Rynite® PET,

Crastin® PBT, Zytel®, Zytel® HTN

7
Vespel®
The search for comfort and safety in
the automotive industry has led to
increased numbers of electric motors.
These are now widely used to make
driving more pleasant (window lift,
sunroof, central locking, air condition-
ing actuation, seat, mirrors & steering
adjustment), and safer (windscreen
wipers, idle and exhaust controls,
differential locking).
Increasing regulations and specifica-
tions for equipment such as starter-
motors and fuel pumps place greater
demands on mechanical wear and
friction components.
Parts such as bushings, washers and
thrust plugs working in electrical
motors have to withstand axial and
radial loads coupled with speed.
The wear and friction characteristics
of Vespel® have helped electrical
motor manufacturers to simplify their
design while improving performance
and life.
Bushings
Used in all kinds of electrical motors,
Vespel® bushings can run with or
without lubrication, depending on the
application. A “straight” bushing
design is adapted to radial loading but
a “flanged” design can additionally
bear axial loads and therefore elimi-
nate the need for a washer.
8
Parts can easily be press-fitted into the Thrust plugs
housing while maintaining very good
control of the inside diameter. In addi- Specifically used in windscreen
tion, the high PV capability enables wipers, window lift, sunroof, seat
the length of the bushing to be reduced. adjusting, differential lock motors,
etc., thrust plugs are parts that are
In these types of application, a low directly fitted into the rotor shaft with
and constant coefficient of friction is a slight interference.
required, as well as wear and creep
resistance. Like washers, these parts have to take
axial loads, and resist creep and wear.
The various Vespel® graphite filled
grades provide cost effective solutions. Depending on the application, a low
or relatively high coefficient of fric-
Washers tion may be required, and unfilled SP 1
or SP 21 filled with graphite are the
Washers take the axial load in electri- usual preferred choices.
cal motors, which means that while
providing wear and friction resistance During very severe use, Vespel® thrust
as bushings do, they also have to plugs will not melt, and therefore
withstand impact. guarantee the function.
Due to the small loading area of such
components, both pressure and velocity
conditions can be high, generating
excessive frictional heat.
The creep resistance and the PV capa-
bility of Vespel® washers guarantee
long and reliable life of the equipment.
Noise, often generated by metallic
parts running against each other, is
eliminated.
Thrust plugs made out of Vespel® SP 1 are
used in ITT’s powerful, reliable and economic
automotive rear windscreen wiper motor.
 Automotive window lift motor using DuPont
engineering polymers
DuPont engineering polymers and
many other DuPont resins are ideally
suited for automotive motor applica-
tions, as they greatly contribute to
overall cost reduction by providing
functional integration and weight
reduction for most of the motor com-
ponents. The window lift motor is a
good example as illustrated in this
drawing, but similar application possi-
bilities can also be extended to other
motors such as wiper motors, seat
motors, sunroof motors, and many of
the some 80 different motors we find
in modern cars.
Insulation spiders
- Zytel® nylon
Vespel® thrust plug
Connector seal
- Hytrel®
Gear
- Delrin® Acetal
Almost all window lift gear housings Hytrel® is an excellent candidate for
today are in nylon such as Zytel® 70G30, seals and hard/soft combinations.
for polyester PBT and PET resins like
Crastin® PBT SK605 and LW9030 and Vespel® is the ideal material for thrust
Rynite® PET 940. Die-cast metals are plugs due to its excellent low wear
still being used in some other motors, performance. Insulation spiders can
which are gradually being replaced by be moulded in Zytel®, Rynite® PET or
Zytel®, Crastin® PBT, and if higher Zytel® HTN. External parts such as
mechanical strength at elevated tem- connectors can be moulded in Zytel®,
peratures is required, by Rynite® PET Crastin® PBT or Rynite® PET and inte-
or Zytel® HTN. grated into the main body.
Delrin® 100 and Delrin® 100P with its
unique combination of toughness,
stiffness and superb friction and wear
properties, has long been the classic
gear material for automotive motor
gears.
Connector seal
- Zytel® HTN
- Crastin® PBT
- Rynite® PET
Vespel® thrust plug
Cushion
- Neoprene
Gear housing
- Zytel®
- Crastin® PBT
- Rynite® PET
- Zytel® HTN
9
Significant savings
Engineering polymers offer significant
savings in electric motors. The higher
raw material cost is normally more
than offset by the production benefits,
combined with a reduction in the num-
ber of components and lower assembly
costs.
Fig. 1, for example, shows some of the
key areas where cost savings can be
generated, using a motor end frame in
Rynite® PET, Crastin® PBT, Zytel® or
Zytel® HTN, rather than thermoset or
die-cast metal.
Additionally, these products provide all
the design and assembly advantages
associated with engineering polymers,
resulting in further cost savings and a
better product.
For further assistance in making a
detailed comparative cost estimate for
your application, including materials,
processing, finishing, assembly and
production suitable for your operation,
contact your local DuPont office (see
back page).
10
Versus thermosets
Rynite® PET, Crastin® PBT,
Zytel®, Zytel® HTN offer:
• Superior mechanical properties
allowing volume reduction of part
• Higher production rates
• Easier handling during processing
and assembly due to superior
toughness
• Advantage of using regrind to min-
imize scrap
• No de-flashing
• Parts integration
• Minimal breakage problems with
finished products during handling
and shipping
• Environmental friendliness due to
recyclability
Fig. 1
Versus metals
Rynite® PET, Crastin® PBT,
Zytel®, Zytel® HTN offer:
• Reduced part weight (also leads to
lower transportation costs)
• No de-flashing
• No machining
• Parts integration
• 4 to 5 times the mould life for
similar toolmaking costs
• Integrated colour, avoiding the
need for painting
• Ability to provide double
insulation
• Attenuation of noise and vibration
Electrical insulation and approved insulating
systems from DuPont
The electrical insulation system of a
motor consists of a number of major
and minor components:
Major
• Ground insulation
(e.g. slot and edge insulators)
• Magnet wire
• Dipping varnish
• Phase separators
Minor
• Insulating tapes
• Lead wire
• Wire end sleeving
• Tie cord
• Wedges and other related parts
UL 1446/IEC 85 Electrical
Insulation Systems (EIS)
A fundamental requirement for many
motors is that they meet either UL 1446
or IEC 85 (EIS) requirements, or both
(see Fig. 3). To meet this need, we
have gained both UL 1446/IEC 85
recognitions for our engineering poly-
mer resins in temperature classes from
130ºC to 220ºC. The DuPont EIS
available to customers contain a wide
range of tapes, sleeving materials,
magnet wires and varnishes and are
listed in the UL “Yellow Cards”
(see Fig. 4 and Fig. 6) under “Plastic
Materials and Electrical Insulation
Systems (OBEU2) for UL 1446 and
under “Insulation System Components,
electrical, evaluated in accordance with
IEC publications (OCTU2)” for IEC 85.
We continue to expand our number
of recognized EIS, and as additional
systems receive recognitions, they will
be listed. We have also published an
extensive brochure on EIS which is
entitled: “Thermoplastics for UL/IEC
Electrical Insulation Systems:
Transformers, Motors, Coils, Relays and
Encapsulation” available to customers
from DuPont as publication H-74531.
What are electrical insulation
systems (EIS)?
When designing a motor, for example,
you have two basic ways of selecting
the materials going into your product:
you can pick the wires, tapes and the
thermoplastics used either by the indi-
vidual material thermal and perfor-
mance recognitions, e.g. the UL rela-
tive thermal indices of each material by
itself, or by the collective system
recognition, which is a measure of how
the group of materials selected behave
together in a common environment.
As an example, consider a simple coil
form moulded in Zytel® 132F nylon
used in a shaded pole motor. Both the
wire and thermoplastic may be sepa-
rately qualified in the thermal class
required for this application. However,
UL 1446/IEC 85 recognition of a sys-
tem containing all the materials tested
together helps build confidence the EIS
used will produce a quality product for
the global marketplace.
Fig. 2 - Rotor end-insulators in
Rynite® PET FR530 used by Braun (Spain).
Other motor components that may be
subject to EIS requirements include
moulded thermoplastic spiders (see
Fig. 2) used in armatures, overmoulded
stator insulation, and separate stator
components.
Thermoplastic encapsulation
Motors are beginning to see the use of
thermoplastic encapsulation, particularly
in stator insulation. Being replaced are
the tapes, films, etc. that are used in
conventional motor insulation, as well
as the epoxy potting used in some
constructions. Complexity of encapsu-
lation can vary from small stator coils to
larger and more intricate motors such
as the Pacific Scientific encapsulated
stators (see photo H, page 15). Using
the steel laminate covers as an insert,
the stator is made in a one-step over-
moulding operation. Encapsulation
provides slot and end insulation, termi-
nation holders, contour supports, and
guide posts for windings – all in a
single moulding step.
Additional information on thermoplastic
encapsulation can be found in
“Electrical/Electronic Thermoplastic
Encapsulation” available from DuPont
as publication H-58633.
11
Advantages of high Maximum UL 1446 IEC85 Maximum
temperature insulation temperature temperature temperature temperature
systems at hottest classes classes at hottest
spot spot
By designing a motor to operate at
high temperatures, one of two benefits
can be gained: reduced size for a given - - Y 90°C
power output, or increased power out- - - A 105°C
put for a given size. - - E 120°C
130°C B B 130°C
With the ability of Rynite® PET to per- 155°C F F 155°C
form in insulation systems up to Class 180°C H H 180°C
N, it is normally possible to use it to 200°C N 200 200°C
upgrade the rating of a motor at little 220°C R 220 220°C
or no additional cost. 240°C S 250 250°C
>240°C >240°C * *
The DuPont family of
insulating materials
*Above 250, each class is a temperature of 25°C higher than the preceding one: i.e. 275, 300, etc.
DuPont offers you an extremely wide
range of insulating materials. Fig. 3
Crastin ®
PBT

These thermoplastic polyester resins UL Temperature Moulded Films

feature excellent processibility, tough- Class rating engineering
ness, and good electrical properties. polymers
They are used in connectors, coil
forms, and other electrical components.
A 105°C Rynite® PET, Mylar®, Nomex®,
Rynite® PET Zytel® nylon Kapton®
Rynite® PET thermoplastic polyester B 130°C Rynite® PET, Mylar®, Nomex®,
resins offer an excellent combination Zytel® nylon Kapton®
of thermal stability, electrical properties, Crastin® PBT
dimensional stability, and stiffness for
today’s small, more complex electrical F 155°C Rynite® PET Mylar®, Nomex®,
and electronic components. Rynite® PET Crastin® PBT Kapton®
is widely used in coil forms and encap- Zytel® nylon
sulation. Zytel® HTN

Zytel®, Zytel® HTN H 180°C Rynite® PET Nomex®, Kapton®

Over half of all coil forms used world-
wide are in unreinforced and glass-
reinforced nylon. Zytel® HTN (High
Temperature Nylon) resins are high
temperature nylon copolymers with a
300°C melting point and a 125°C
glass transition temperature (dry).
Zytel® HTN is used in applications
requiring high strength and high tem-
perature capabilities.
Zenite® LCP Liquid Crystal
Polymer
Zenite® LCP resins are aromatic poly-
ester resins with high (335-352°C)
melting points. Features include
excellent dimensional stability and
creep resistance, even at very high
temperatures. Their processibility
makes moulding surface-mount coil
forms with 0.25 mm thick flanges a
commercial reality.
N 200°C Rynite® PET Nomex®, Kapton®
R 220°C Zenite® LCP Nomex®, Kapton®
Fig. 4
Nomex® brand sheet structures Kapton®
These sheet structures offer high tem- An ultra-tough polyimide film capable
perature resistance, superior dielectric of withstanding extreme temperatures
properties and high tensile strength, (400°C) and pressure, it is impervious
combined with excellent flexibility and to most chemicals. As an insulator,
resilience. Available in strip and sheet Kapton® has unmatched dielectric
form, Nomex® provides superior layer properties and remarkable tensile
and phase insulation between coil layers strength, which permit thinner wall
and around coil formers. construction for increased performance
and cost efficiency.
Mylar®
This exceptionally strong polyester
film offers an unusual balance of
chemical, electrical, physical and ther-
mal properties. Well suited for many
electric, electronic and industrial uses,
Mylar® provides superior interwinding
barrier and phase insulation in wire and
cable coils.

12
 Fig. 5 - RTI versus HDT of DuPont Engineering Polymers
(30-35% glass-reinforced)

250 ¡C
Zenite® LCP
Relative thermal index
200 ¡C

150 ¡C Rynite® PET Zytel® HTN

®
Crastin PBT
Zytel® PA66

100 ¡C
200 ¡C 250 ¡C
Heat deflection temperature at 264 psi, °C

Fig. 6. - Examples of a pre-approved

Class F (155°C) insulation systems
based on Rynite® PET and Zytel®.

13
Motor design
Rotors and stators
Engineering polymers such as
Rynite® PET, Crastin® PBT, Zytel®,
Zytel® HTN and Zenite® LCP are well
suited to motor insulation, as shown in
the preceding section.
These moulded insulators make motor
assembly easier, and reduce labour
costs. Several examples of applications
are shown here.
Overmoulding
There is a cost efficient technique for
insulating rotors and stators which has
not been discussed, and that is over-
moulding – where the lamination stack
(preferably pre-heated) is inserted into
a mould and selectively coated with
plastic.
14
Overmoulding is normally used to It is sometimes useful to employ flow
avoid the need for separate insulator leaders to aid in material flow. These
mouldings and/or pieces of insulating can be holes a few millimetres in
film. diameter through the rotor or stator
lamination stack. These leaders aid the
Consequently, this technique can offer flow of thermoplastic and promote
further cost savings and production complete filling of thin sections.
advantages.
The thickness of thermoplastic
required, particularly in the case of
overmoulded slot insulation, is very
small (typically <1 mm). As a result,
one of the most important considerations
when designing such insulation is the
ability to fill the plastic part completely
during the moulding operation.
Complete filling is critical to eliminate
any possibility of dielectric failure
when the part is operational.
Therefore, material selection is very
important. Grades of Rynite® PET and
Zenite® LCP offer particularly low melt
viscosities (high flow), and Rynite® PET
offers excellent insulation performance B
(up to Class N = 200°C) and
Zenite® LCP (Class R = 220°C).
I
 A. Grundfos (Denmark) stator insulators
moulded in Rynite®.
B. Multi-functional armature insulators,
also known as spiders, in Zytel® HTN,
for windshield wiper motors from ITT.
C. Motor stator insulation in
Zytel® 70G30 for Elco (Italy).
D. Mycalex (UK) shaded pole motors
with coil bobbins and terminal block
moulded in Rynite® PET FR530.
A E. Sanyo (Japan), overmoulded stator
bobbins in Rynite® PET FR530 and
FR515 for permanent magnet stepping
motors.
F. Miele (Germany) stator insulation
made of Zytel® 101L.
G. Stator encapsulation of 25-W shaded
pole AC induction motor for Electric
Motors and Specialties, Inc. (USA).
H. Encapsulation of motor winding
insulation, end frame and connector
housing in Rynite® PET for Pacific
Scientific (USA).
C I. Asynchronous motor shaft over-
moulding for SEL (Germany),
Rynite® PET (Class H).
D

15
Commutators
Commutators require insulation
between the bars as well as at the ends.
A traditional way of providing this
insulation is with mica sheet, as shown
in Fig. 7.
However, as with rotors and stators,
the insulation can often be provided
more cost effectively by engineering
polymers. A material with good flow
characteristics – to completely fill thin
part sections in the mould – and good
high temperature insulation performance
is normally required. Rynite® PET meets
both of these requirements.
For larger commutator applications
where the requirements for high flow,
dimensional stability and high temper-
ature resistance are even more
demanding, Zenite® LCP provide an
excellent balance of properties.
End frames
It is well recognized that most motor
end frames are demanding engineer-
ing applications. The air gap between
rotor and stator is usually less than
1 mm, so rotor alignment is critical.
16
Traditionally, materials such as
stamped steel, die-cast aluminium or
zinc alloys, and thermosets have been
used for motor frames. However, these
materials have limitations in terms of
weight, function integration, environ-
mental friendliness, assembly, noise
and vibration.
Engineering thermoplastics not only
offer the required mechanical proper-
ties, but also permit weight savings,
functional integration and eliminate
the shortcomings of metals and
thermosets. This capability results in a
reduction of the number of components,
and consequently in lower finished part
cost.
Naturally, when an end cap, a motor
bracket, or even a complete housing is
being designed, the same question is
often raised: “Does a thermoplastic
have sufficient stiffness and dimen-
sional stability for this application?”
The answer is normally yes, provided
that the right engineering polymer is
selected for the task, and that correct
design and ribbing techniques are
employed.
A
 A. Vacuum cleaner motor end frame
in Rynite® PET and Crastin® PBT from
Electrolux (U.K.).
Tightening nut
Iron ring B. Commutator plates moulded in
Zytel® nylon for Maxon motor
Mica V ring (Switzerland).
Front V ring
Commutator
C. Fiat rear screen wiper motor
Commutator frame in Rynite® PET FR530.
bars bars
Mica Mica D. Zanussi dish washer pump motor
insulation Iron shell frame in Rynite® PET FR 530 from
between Sole (Italy).
bars
E. Thrige-Titan (Denmark) forklift
truck motor end frame in
Rynite® PET 530.
Back V ring with
mica inner and outer F. Rexon (Taiwan) mitre saw motor
rings for insulation frame/housing in flame-retardant,
glass-reinforced Zytel®.
Fig. 7

E
F

17
 500

Tensile strength MPa

Die-cast materials
400

300 Zn
Al
Reinforced Mg
thermoplastics
Zytel® HTN 51G35
200
Rynite® PET 555
Unreinforced
thermoplastics Rynite PET 530
®
Zenite® LCP
Crastin® PBT SK 605
Zytel 70G30 HSL
®

100 30% GR PC
PA66 Delrin® (POM)
PA612 Thermosets
PC PBT moulding
PA11 ABS compounds
PP
1 5 10 50 100
Flexural modulus GPa

Fig. 8 - Stiffness/strength combination of materials.

Zenite® LCP 6130

Zytel® HTN 51G35
Rynite® PET 545 Zytel® 70G30
Crastin® PBT SK605
Zinc-Al

Mg
Delrin®
Flexural modulus MPa

Zytel® 101

Examples of finite element analysis

for a motor frame:
Top photo shows deflection in a
Y direction in mm.
Bottom photo shows stress in N/mm2.

The stiffness and stability of thermo-

plastics have now been confirmed by
1 1.5 2 2.5
experience in commercial applica-
tions. However, when a new motor Thickness (mm)
frame is being developed, a finite
3h 2
element analysis (FEA) is often h2
valuable in optimizing the design.
As shown in Fig. 8 and Fig. 9, glass-
reinforced engineering polymers are h1
particularly well suited to motor
frame applications. Rynite® PET absorbs 8h 1
8h 2
only extremely small quantities of
water following moulding, giving it Metal Plastic
excellent dimensional stability. It
also has a high heat deflection tem-
perature. In addition, these resins can Fig. 9 - Beams of equivalent stiffness.
be modified with mineral additives to
further increase dimensional accuracy
for very demanding applications.

18
Creep resistance
Deformation under load with time is
called creep. The amount of creep
depends on material composition
(polymer type, reinforcement, etc.),
time, temperature and the applied
stress level.
The data shown in Fig. 10 indicate
that glass-reinforced engineering
polymers have particularly good
resistance to creep, even at high
temperatures and stress levels.
Components of automotive motors
such as the windowlift motor shown
on this page or windshield wiper
motors and seat motors can be subject-
ed to considerable stresses which over
time will cause creep. For example, the
gear housings of these motors have to
withstand external and rotor shaft
forces over thousands of cycles.
Coupled with relatively high tempera-
tures even in the interior of a car, these
forces can lead to creep of the material.
Glass reinforced grades of Zytel®,
Crastin® PBT, Rynite® PET and Zytel®
HTN have good creep resistance to
withstand this.

2.2
For comparison Zytel® 101F
2.0 23°C/20 MPa stress

1.8
125¡C Rynite® PET 530
1.6
Strain (%)

1.4
125¡C * Zytel® 70 G30 HSLR
1.2 60¡C Rynite® PET 530

1.0

0.8 125¡C Rynite® PET 555

23¡C * Zytel® 70 G30 HSLR
0.6 23¡C Rynite® PET 530
23¡C Rynite® PET FR 530
0.4

0.2

0
1 10 100 1000 10000
Times (hours)
* It is critical to note that for Zytel® 70 G30 HSLR: 23°C = 50% RH, 125°C = DAM

Fig.10 - Long-term creep data (at 27.6 MPa stress)

19
Bearings and bearing
housings
In micromotors, the end cap itself,
frequently made of thermoplastic,
often also acts as the bearing.
Thermoplastic bearings can offer a
number of advantages over bearings
in metal, including:
• Ability to operate with minimal
or no lubrication
• Longer wear life
• No corrosion by chemicals and
lubricants
• Noise dampening and reduced
vibration
Plastics commonly used in these
types of bearings are Zytel® and
Minlon® nylon resins, and Delrin®
acetal resins.
As plastics do not conduct heat read-
ily from the frictional source, heat
dissipation is a major consideration
in the design of thermoplastic bear-
ings. For an initial evaluation of
whether a plastic bearing will perform
in a specific application, the PV
concept (Pressure x Velocity) rating
can be used.
For bearings which require very low The benefits of thermoplastic bearings
coefficients of friction and higher can sometimes be brought to larger
PV values, standard engineering motors, but traditionally these motors
polymers can be modified with, or employ metal bearings press-fitted
replaced by, Teflon® and Tefzel®. into a metal frame (see Fig. 12). This
arrangement gives a good interference
Full details of these PV calculations, fit over the full range of operating
together with advice on designing temperatures, as the bearing and
bearings in Zytel® and Delrin®, are bearing seat have similar coefficients
available within separate design of thermal expansion.
brochures. If you need assistance,
please contact your nearest DuPont
office (see last page).
P
d = Shaft diameter mm
l = Length of bearing mm
V = Peripheral speed m/s
F = Overall load N
n = Revolutions per s
V
l

The PV value is defined in the follow-

ing way (see Fig. 11):
Specific bearing load:
F (MPa)
p= d
dxl
Peripheral speed:
d x ¸ x n (m/s)
v=
1000 Fig. 11
PV value:
PV = pv (MPa – m/s)

Maxon motor with bearings/end-caps in Minlon®

20
When a thermoplastic motor frame is
used with a metal bearing, attention
must be paid to the bearing seat design,
as the thermal expansion of most poly-
mers is considerably greater than that
of metals.
However, for most motors, attention to
dimensions and proper interference fit
for the plastic will provide good bear-
ing alignment over the required range
of operating temperatures. Thermo-
plastics also allow easier parts assem-
bly, including the use of snap-fits.
A number of new designs for thermo-
plastic bearing seats have also been
developed for use with conventional
bearings (see Fig.13).
Metal frame
• High E-modulus
• Small increase in interference
gives large increase in specific
pressure on external ball
bearing cage
• Dynamic interference required
= 0.08%
= 0.02 mm;
resulting specific pressure =
18.8 MPa
• Low permitted interference
means tight tolerances required
• Machining of bearing tolerance
seat needed
Engineering polymers
(glass-reinforced frame)
• Lower E-modulus
• Large increase in interference
gives small increase in specific
pressure on ball bearing cage
• Interference for equivalent specific
pressure = approx. 1%
= 0.26 mm
• Even with 1% interference, there is
a safety margin since elongation to
break of glass-reinforced engineer-
ing polymers is around 2.5-3%
• Precision moulding total tolerance
achievable for 26 mm = 0.1 mm
• Required bearing seat tolerances
can be achieved by moulding
• Machining of bearing seat avoided
• Lower temperature of the bearing,
due to low heat conductivity of the
polymer frame, gives longer life-
time

Fig. 12

Spring ring
Finger spring washer Spring washer
(slotted or not)

Olive bearing Ball bearing

Elastomer part
(self alignment vibration and
noise reduction)

Housing Housing Housing (snap-fit)

Fig. 13
21
For the most demanding applications,
additional techniques have been
developed. One of these, patented by
SKF, involves the overmoulding of a
metal coil. As the coil has a rate of
thermal expansion similar to that of
the bearing itself, it keeps the play
between bearing and housing to a mini-
mum. This is achieved by preventing
free expansion of the bearing housing
with temperature variations.
Experience has shown that this over-
moulded insert is particularly useful
for those applications where the
range of operating temperatures is
very wide.
DuPont also offers materials such as
Vespel® SP polyimide for very high
performance bearings.
Gears and gear housings
Automotive motors, such as window
lift motors and wiper motors, use
gears and gear housings (see A and B).
Engineering polymers are increas-
ingly being established as the most
suitable material for these applica-
tions. For example, Delrin® 100 is
widely used in gear applications.
Depending on the dimensional sta-
bility and thermal requirements, gear
housings can be moulded in Zytel®,
Crastin® PBT, Rynite® PET or Zytel® HTN
(see Fig. 14).
22
Brush holders In some larger motors, the brushes
can rise significantly in temperature
With a metal motor frame, it is normally during operation. Here, it is impor-
necessary to have separate plastic tant to design the area of the plastic
mouldings to insulate the brushes and bracket acting as the brush holder
brush holders from the frame. A typical support for maximum ventilation.
example is shown in photo E. This can be done easily.
Engineering plastics have the required In some applications, it is necessary
electrical and thermal properties to to insulate the exposed end of the
perform well in such applications. brush holder. A simple plastic cover
Tracking resistance (CTI) is particularly can be designed to snap onto the
important. motor frame to provide this insulation.
This snap fit may be designed as
However, another advantage of thermo- permanent, or recoverable – to permit
plastic motor frames is that they maintenance or replacement of the
avoid the need for these separate brushes.
mouldings. The brush holder supports
can be moulded as integral parts of the Once again, a design which permits
end frame, allowing the brush holders maximum ventilation of the brushes is
to be directly push-fitted into the recommended.
frame (see page 7). This clearly
reduces component and assembly
costs.
During motor operation, the brushes
become hot, but plastics are good
thermal as well as electrical insu-
lators. In some small motors, the
temperature rise is not significant,
and the brushes can be located
directly in the moulded motor frame, as
shown in photo H.
However, many motors require metal
brush holders. These are often made of
brass and can be similarly push-fitted C
directly into the plastic frame.
I
Motor cooling fans C. Cut-away view of plastic motor
frame using the overmoulded SKF
Many motors incorporate their own insert.
cooling fans, to increase air flow
and reduce operating temperatures.
Traditionally these fans have been D. Thrige-Titan forklift truck motor
made of metal, but they can also be frame in Rynite® PET 530 using the
cost effectively moulded from engi- overmoulded SKF insert.
neering polymers.
Normally, materials used for these E. Brushes fitted directly into motor
applications are often the same as frame of Zytel®.
those used to mould the motor's
insulation, or end frame.
F. Paris-Rhône (France) automotive
alternator, using fan, brush holder
Zytel® HTN 51G45 and diode support plate moulded in
Rynite® PET 545.
100¡C
Rynite® PET 545
23¡C
G. Snap-fit bearing design used by
Crastin® PBT SK609
Stebel (Italy) for their horn compres-
sor motor in glass-reinforced Zytel®.
Zytel® 70G50

Zytel® 73G50 H. Snap-fit bearing design used with

a motor frame in Rynite® PET for a
0 0,05 0,1 0,15 0,2 Def. (mm) Zanussi dish washer pump from Sole
Zytel® data at 23°C at 50%RH
(Italy).
Fig. 14 - Deformation comparison of engineering polymers
Wiper motor gear housing – concept study (45%-50% GR)
I. Flame retardant Rynite® PET was
D selected for this cooling fan from
E
Japan Servo because of its good
dimensional stability and heat resis-
tance. Temperatures in photocopy
machines can often reach 150°C.

23
Function integration
Function integration and minimizing
assembly costs are becoming
increasingly important in today's
competitive market. However, motor
frames have traditionally been multi-
component assemblies.
A major advantage of redesigning
motor frames in thermoplastic is the
ease with which one component can
be designed to perform the functions of
many.
The integration of some functions,
such as brush holders, has already
been discussed. This section concen-
trates on other features which can
also be incorporated into motor
frames.
24
A. Traditional motor assembly.
B. Motor design based on engineering
polymers, showing function integration.
C. Multi-functional motor frame in
Zytel® FR51 from Braun (Spain).
D. Easy-assembly motor bracket in
Minlon® 11C140 from Maxon
(Switzerland).
E. Braun selected Zytel® for the
motor end-frames of a recent hand-
mixer because of its long term
temperature resistance, excellent
dimension stability and overall
mechanical performance.
Assembly features
Motor frames are normally assembled
to each other, or to the stator lami-
nations, using bolts or metal clips,
but this is a relatively expensive
method of assembly.
Thermoplastic end frames lend them-
selves to more efficient assembly
techniques, such as snap-fits, inter-
ference-fits or ultrasonic welding.
Some examples of these assembly
techniques are illustrated in Fig. 15
and Fig. 16. They are particularly
suited to smaller motors which have
small applied loads, where they can
offer valuable cost advantages.

B
Fig.15 - Plastic motor frame assembly using ultrasonic welding.

Fig. 16 - Plastic motor frame assembly using snap-fit.

D E

25
Frame extensions and Interconnects A. Myson (U.K.) uses Rynite® as both
housings housing and insulation for this pump
Materials such as those recommended motor.
Motor frames can often be readily for motor frames, e.g. Rynite® PET,
extended to fulfil additional func- Crastin® PBT and Zytel® polyamide, are B. Milwaukee (U.S.) power tool has
tions. The availability of a wide range widely used for connector applications. motor frame and housing incorporated
of DuPont engineering polymers into a single moulding of glass-
with suitable properties for multi- By moulding the electrical connector as reinforced Zytel®.
functional parts means that motor an integral part of the motor frame, a
systems can be designed to make number of separate connectors are
products much more competitive in usually eliminated. These may
the marketplace. include a metal mounting plate, the
separate connector moulding, and
Minlon® can give high-speed fans two or more assembly screws.
used in vacuum cleaners the flatness
required to generate a constant air-
flow, and the impact resistance need-
ed to prevent breakage by incoming
objects. Its warp-free mouldability
and excellent dimensional stability A
also allow it to be used for multi-
functional parts in the same appli-
ances, reducing costs in components
and labour.
The heat buildup of fully enclosed
motors requires the use of high tem-
perature class polymers. Rynite® PET,
Crastin® PBT, Zytel® HTN can meet
these demands reliably, acting as
both motor insulation and housing.
Glass-reinforced Zytel® gives design-
ers high strength, stiffness, very high A
deflection temperatures, rigidity, ten-
sile strength, dimensional stability and
impact strength. Just what they need
to combine a motor frame and housing
into a single unit.
Here are some examples of commer-
cial applications.

26
Motor design innovations
Fisher & Paykel Co, of Auckland,
New Zealand, the country’s leading
appliance manufacturer, has developed
a radically new type of power drive
for washing machines. This new
“Smart Drive” incorporates multi-
functional components made of
DuPont Rynite® PET thermoplastic
polyester resin, and is used in the
company’s top-loading automatic
washers.
The Fisher & Paykel design replaces
the conventional U.S. washing
machine’s combination of a fixed-
speed a.c. motor and a 40- or 50-piece
gear case with a system using an elec-
tronically controlled brushless d.c.
motor that drives the agitator and spin
bowl directly through a patented
clutch.
The washing machine’s motor design
is most unusual. Windings are located
on the stator rather than on the rotor,
and the rotor turns around the outside
of a centrally mounted stator rather
than inside it. This approach allows a
direct mechanical link between the
rotor and a common shaft to drive both
spin and agitator movements.
The stator’s entire support structure, its
ground insulation and coil supports are
produced of Rynite® PET in a single
injection-moulding step. A ring-shaped
stack of specially profiled stamped
steel laminations is placed in a mould
and then injection overmoulded with
the polyester resin.
The wheel-shaped part that comes out
of the mould needs only windings and
terminations to become a fully finished
stator. It measures 25 cm across, and
has 42 integrally moulded winding
poles spaced around its circumference,
as well as moulded-in wire ways, ter-
minal holders and holes for mounting
bolts and drainage. A three-phase
winding is applied in a separate, fully
automated step.
The rotor is a dish-shaped component
27 cm in diameter. Integrally moulded
teeth at its hub serve for spline mount-
ing on the end of the shaft that spins
the washer tub and moves the agitator.
Spaced around the rotor’s circumfer-
ence are 56 rare-earth permanent mag-
nets, which are bonded to a ring-
shaped stack of steel laminates.
The rotor is made by placing the
laminate stack and attached non-
magnetized rare-earth strips in the
mould, and then overmoulding with
Rynite® PET, leaving the magnet strips
exposed. These are subsequently
activated by placing the rotor over a
high-energy magnetising head.
Assembly of the rotor and stator is
simplicity itself. The stator is first bolt-
ed onto the washer’s outer bowl, which
is accurately located over a bearing
supporting the spin basket and agitator
shaft. The rotor is then placed over the
spline near the end of the drive shaft,
and pulled down into position with a
securing nut. At this stage, the motor is
ready for electrical connection to the
washing machine’s electronic controls.
The Rynite® PET resins selected by
Fisher & Paykel meet a rigorous com-
bination of structural, dielectric and
manufacturing requirements. The
dimensional stability of Rynite® PET
allows both the rotor and the stator to
be moulded without the need for fur-
ther machine processes.
The rotor withstands dynamic torsional
and radial loading as it oscillates at
variable speeds within a 200-degree
arc during agitation cycles, and it
whirls at speeds up to 1 100 rpm dur-
ing spin cycles. These requirements are
met with Rynite® PET 545 and FR543
for the rotor and stator, respectively.
Rynite® PET FR543 is recognized by
Underwriters Laboratories as UL 94
V-0 at 0,8 mm and 5-V at 1,6 mm.
C

C. An innovative brushless d.c. washing

machine motor relies on Rynite® poly-
ester for both insulation and structure
in the wheel-shaped stator and the
dish-shaped rotor.

C
27
Noise, vibration and
harshness
Two increasingly important factors
in the design and marketing of motors
are vibration and noise, particularly for
such applications as office equipment
and household appliances.
Although product design has a major
influence on the noise of a motor,
there are a number of areas where
materials selection can also play an
important role.
For example, the use of thermoplastic
bearings wherever possible can reduce
vibration and help to dampen noise.
28
The right material choice for the
motor frame is also important. An
application where Rynite® PET
replaced a die-cast motor frame,
allowing both cost savings and quieter
performance, is shown in photo B.
Further noise reduction is possible
by isolating the motor frame from its
normal mounting points, thus pre-
venting the transmission of vibra-
tion. This can be achieved by using
mounts moulded from a thermoplastic
elastomer, such as Hytrel®. Several
design concepts suitable for such
applications as office equipment fans
are shown in Fig. 17 and Fig. 18.
Transmission of vibration can also be
reduced by modifying gears. In the
French food processor shown in
photo A, a small gear moulded in
Hytrel® has reduced the operating
noise level of the appliance by 15 dB.
The part in Hytrel® replaces a gear in
acetal.
A
When dealing with noise problems of
plastic components, it is important to
understand the source of the noise, i.e.
what is causing the part to vibrate, as
well as to understand how the part
itself is resonating before a solution is
possible.
The DuPont NVH laboratory was set
up to deal with the noise problems of
plastic components. It has portable
NVH test equipment, making it possi-
ble to analyze a component in situ. For
a more detailed analysis, samples are
taken back to the NVH laboratory and
excited using a relevant test rig. The
components response to the excitation
can then be measured by using tech-
niques such as acoustic or laser holog-
raphy. This testing helps to identify
how the part needs to be modified so
as to reduce the noise problem. Sample
components can then be modified in-
house and supplied to customers for
testing. The facility can test vibration
and noise properties of electrical
motors using various materials for the
housing. A whole system can also be
analyzed, such as the door mechanism
on which a window-lift motor has been
mounted.
A. Gear of flexible Hytrel® reduces
noise by 15 dB in this appliance from
SEB (France).

B. Torin (UK) fan housing and

bearing (overmoulded PCB) in
Rynite® PET FR530.

C. Hytrel® is used for blower mountings

to provide quieter computer storage
sub-systems. It offers excellent sound
deadening properties, can absorb and
isolate impact shocks, as well as being
easy to overmould onto steel.

C
Ventilator mounting
for vibration
isolation

Steel sheet
Ventilator
housing

Ventilator

Sheet-iron
Fig. 17

Fig. 18
29
 ®

DuPont Engineering Polymers

Product guide and

properties for electric
motors

® DuPont registered trademark

Test performance ratings of DuPont Engineering Polymers
Tracking Resistance, IEC 112 / UL 746 A V (volt) thickness of specimens: >3 mm

CTI UL 746 A CTI-M

IEC PLC level IEC
Crastin® PBT S600F10, S600F20, S620F20 >600 2 350
ST820 >600 >600
SK601 300 2 200
SK602 350 2 200
SK603 400 2 200
SK605 450 1 200
SK608 475 200
SK609 500 1 200
LW9130 400 2 200
LW9020, LW9030 550 1 175
T805 500 1 200
SO653 300 2 200
SO655 250 2 200
HTI619 >600 0 200
S650 FR 225 2 175
S680 FR 250 175
T850 FR >600 275
SK641 FR 225 2 175
SK642 FR, SK 645 FR 250 2 175
SK643 FR 250 3 175
CE7931 250 2 150
SK673 GW 250 175
LW9020 FR 350 2 175
LW9020 FR GY 325 2
LW9030 FR 375 2 175
LW9320 FR 350 2
LW9330 FR 375 1
LW9330 FR GYB 350 1
T841 FR 250 3 175
T843 FR 275
T845 FR 325
HTI681 FR >600 0 450
HTI668 FR >600 0 200
HTI688 FR 475 1 250
Delrin® acetal 100, 107 >600 0 >600
100 P >600 0
500, 507 >600 0
500 P, 900 P 600 0
100 ST, 100 T, 500 T, 570 600 0 600
500 CL, 500 AF >600 0
Rynite® PET 520 250 3
530 250 2 200
545 250 2 250
555 200 3
935 3251) 2
FR515 275 3
FR530 L 250 2 125
FR543 250 2 125
FR943 225 2 100

2
 CTI UL 746 A CTI-M
IEC PLC level IEC
Zytel® PA66 E101 L >600 0 375 (325)
unreinforced 101 F >600 0 575 (475)
E103 HSL 525 (425) 0 400 (350)
E103 HSL BK-80 525 400
105 F BK-10 0
114 L BK-97 575 (525) 0
135 F 600 0 475
E42 A 0
450 600 (590) 0 525 (475)
490 >600 0 475
ST801 NC-010, NC-010 A >600 0 600
Zytel® PA66 FR70G28 V1 300 2
glass reinforced, flame retardant FR70G25 V0 325 2 150
Zytel® PA66 79G13 L 475 1
glass reinforced 70G20 HSL, 70G25 HSL 400 (325)
70G30 HSL 400 (325) 1 350
74G33E HSL BK-354 450
Zytel® PA66 FR70M30 V0 325 2 2501)
mineral reinforced, flame retardant
Minlon® PA66 10B140 575 250 (200)
mineral reinforced 11C140 550 (475) 1 300 (250)
Zytel® PA66/6 FR7200 V0F 575 0
unreinforced, flame retardant
Zytel® PA66/6 FR72G25 V0 325 3 150
glass reinforced, flame retardant FR72G25 V0 BK 275 150
Zytel® PA66/6 72G30 L 1
glass reinforced
Zytel® PA6 FR73GM60 V0F >600 0
glass-mineral reinforced, flame retardant FR73GM60E V0F >600 0
FR73GM50 GWF >600
Zytel® HTN HTN 51G35 HSL NC-010 >600 0 300 (250)
high temperature HTN 51G45 HSL NC-010 >600 0 250
nylon HTN FR51G35 L NC-010 500 1 225
Hytrel® thermoplastic polyester 5556 >600 0
elastomer 7246 >600 0 575
Zenite® LCP 6130 WT-010 150 4 100
liquid crystal polymer 7130 WT-010 150 4 100
6330 NC-010 150 4 100
Vespel® SP-1, SP-21 3
polyimide resins
1) KC, KB values. * Only available in black.
Caution: Colours often significantly affect tracking values in one or the other way.
Further information on this is available on request.

All the above information is subject to the disclaimer on the back page of this brochure.

3
Flammability classification, UL 94

UL rating at minimum thickness (mm)

HB V-2 V-1 V-0 5VA

Crastin® PBT S600 F10, S600 F20, S620 F20 1,5
ST820** 1,5
SK601, SK602, SK603 0,8
SK605, SK608**, SK609 0,8
LW9130 0,8
LW9020, LW9030 1,5
T805 0,8
SO653, SO655 1,5
HTI619 1,5
S650 FR, S680 FR 0,8
T850 FR 1,5
SK641 FR, SK642 FR 1,5
SK643 FR, SK645 FR 0,8
CE7931 1,5
SK673 GW** 1,5
LW9020 FR. LW9030 FR 1,5
T841 FR, T843 FR, T845 FR 1,5
HTI681 FR 0,8
HTI668 FR, HTI688 FR 1,5
Delrin® acetal 100, 107 0,8
500, 507 0,8
500 CL, 500T 0,8
570 0,8
Rynite® PET 520, 415 HP, 935 0,8
530, 545, 555, 408 0,8
FR515 0,86 1,5
FR530 L, FR943 0,35 1,5
FR543 0,81 1,5
9082 F**, 9085 F** 0,82)
Zytel® PA66 unreinforced E101 L, 101 F, E103 HSL 0,84)
105 F BK-10 0,84)
114 L BK-97 0,8
135 F 0,84)
408, 450, 490 0,8
ST801 0,8
Zytel® PA66 glass reinforced,
flame retardant FR70G28 V1 1,47
FR70G25 V0 0,5
Zytel® PA66 glass reinforced 79G13 L, 70G20 HSL, 70G25 HSL 0,8
70G30 HSL, 70G30 PSR 0,8
70G35 HSL 0,8
Zytel® PA66 glass-bead reinforced 70GB40 HSL 0,75
Zytel® PA66 mineral reinforced,
flame retardant FR70M30 V0 1,5 1,5

4
 UL rating at minimum thickness (mm)

HB V-2 V-1 V-0 5VA

Minlon® PA66 mineral reinforced 10B140** 0,83)
11C140 0,81)
Zytel® PA66/6 unreinforced,
flame retardant FR7200 V0F 0,5
Zytel® PA66/6 glass reinforced,
flame retardant FR72G25 V1 0,75 1,50
FR72G25 V0 0,5
Zytel® PA66/6 glass reinforced 72G15 L, 72G30 L 0,8
72G40 HSL BK* 0,8
Zytel® PA6 unreinforced 7335 F 1,5
Zytel® PA6 glass reinforced 73G15, 73G20, 73G30, 73G50 1,5
Zytel® PA6 mineral and
glass reinforced, FR73GM60 V0F, FR73GM60E V0F 1,5
flame retardant, halogen and
phosphorus free FR73GM50 GWF** 1,5
Minlon® PA 6 mineral reinforced 73M30 0,85
Zytel® HTN high temperature nylon HTN 51G35 HSL NC-010 0,8
HTN 51G45 HSL NC-010 0,8
HTN FR51G35 L NC-010 0,8
Zenite® LCP liquid crystal polymer 6130 WT-010 0,41
7130 WT-010 0,8
6330 NC-010 1,5
Hytrel® thermoplastic polyester 4056 1,47
elastomer 5556 1,47
7246 1,47
Vespel® polyimide resins SP-1 0,8 1,7
SP-21 0,8 1,6
1) UL yellow cards are available. ** Only available in black.
2) DuPont test results using ISO 9290. ** Only available in natural colour.
3) NC, BK.
4) All colours. Table for information only. For actual classification, please consult the most recent UL Yellow Cards.
5) NC, BK, GY. For products or grades that do not appear on this table, please contact your DuPont representative
for more information.

All the above information is subject to the disclaimer on the back page of this brochure.

5
Glow Wire Flammability Index: “GWFI” °C

1 mm 2 mm 3 mm 6,4 mm
Crastin® PBT S600, S620 750
ST820 700 700
SK602, SK603, SK605 750
SK608, SK609 750
LW9130 750
LW9020, LW9030 650
T805 750
SO653, SO655, HTI619 750
S650 FR, S680 FR T850 FR 960 960
SK641 FR, SK642 FR 960
SK643 FR, SK645 FR 960 960
CE7931, SK673 GW 960
LW9020 FR, LW9030 FR 960 960
T841 FR, T843 FR, T845 FR 960 960
HTI681 FR, HTI668 FR, HTI688 FR 960 960
Delrin® acetal 100, 107, 100 P 550 550 550
500, 507 550 550 550
500 P, 900 P 550 550 550
100ST, 100T, 500T 550 550 550
500 CL 550
500 AF, 570 600
Rynite® PET 520 650 650 750
530 960
650 750 750
545 960
750 750 850
FR530 L 960 960 960 960
(0,8 mm) (2,2 mm) (3,2 mm) (1,2 mm)
FR 543 NC-010, FR 943 NC-010 960
RE 5211 S 750
(3,2 mm)
RE 5213 S 750
(0,8 mm)
9082 F 850 960 960 960
(0,8 mm)
Zytel® PA66 unreinforced E101 L 850 960 960
(1,6 mm)
101 F 750 960 960
E103 HSL 850 960 960
105 F BK-10 960* 960* 960*
114 L BK-97 650 650 650
135 F 850 850 960
408 650* 650* 650*
450 675* 650* 650*
490 700* 700* 700*
XA480 750
ST801 650 650
Zytel® PA66 glass reinforced, FR70G25 V0 850 960
flame retardant (1,6 mm)
FR70G28 V1 960

6
 1 mm 2 mm 3 mm 6,4 mm
Zytel® PA66 glass reinforced 79G13 L 650
(2,5 mm)
70G20 HSL 650* 650* 750
70G25 HSL 650 650 750
70G30 HSL 650* 650* 750*
70G60 HSL BK** 700 700 850
Zytel® PA66 glass-bead reinforced 70GB40 HSL
Zytel® PA66 mineral reinforced, FR70M30 V0 960
flame retardant (at 1,2, 1,5 and 2,5 mm)
960
(at 1,2 mm)
Minlon® PA66 mineral reinforced 10B140 750
(3,2 mm)
11C140 650
(3,1 mm)
Zytel® PA66/6 unreinforced, FR7200 V0F 960
flame retardant (at 0,8, 1,6 and 3,2 mm)

Zytel® PA66/6 glass reinforced, FR72G25 V1 960

flame retardant (1,5 mm)

FR72G25 V0 960
(1,6 and 3,2 mm)
Zytel® PA6 unreinforced 7300, 7335 F 800 850
(1,6 mm)
Zytel® PA6 glass reinforced 73G15
73G30 HSL BK 700 700 700
73G40, 73G50
Zytel® PA6 mineral and FR73GM60 V0F, FR73GM60E V0F 960
glass reinforced, flame retardant,
halogen and phosphorus free FR73GM50 GWF 960
Zytel® HTN high temperature nylon HTN 51G35 HSL NC-010 750
HTN 51G45 HSL NC-010 750
HTN FR51G35 L NC-010 960
Hytrel® thermoplastic polyester 4056 775 750 750
elastomer
Zenite® LCP liquid crystal polymer 6130 WT-010, 7130 WT-010 960
6330 NC-010 960
Vespel® polyimide resins SP-1, SP-21

* DuPont Laboratory test results. ** Only available in black. *** Only available in natural colour
For products or grades that do not appear on this table, please contact your DuPont representative for more information.

All the above information is subject to the disclaimer on the back page of this brochure.

7
Deflection temperature under flexural load, ASTM D 648, DIN 53461, ISO 75 °C

0,45 MPa 1,8 MPa

DAM DAM
Crastin® PBT S600, S620 160 60
ST820 105 48
SK601 215 185
SK603 220 204
SK605 220 205
SK609 222 215
LW9130 202 180
LW9020 215 172
LW9030 215 182
T805 205 190
SO653 185 70
SO655 212 99
HTI619 220 200
S650 FR 160 65
S680 FR 175 64
T850 FR 167 60
SK642 FR 218 203
SK643 FR 220 205
SK645 FR 220 210
CE7931 221 210
SK673 GW 220 205
LW9020 FR 215 175
LW9030 FR 220 190
T841 FR 200 183
T843 FR 204 188
T845 FR 205 192
HTI681 FR 194 88
HTI668 FR 200 185
HTI688 FR 205 190
Delrin® acetal 100, 107, 500, 507 170 115
100 ST 145 70
500T 165 90
500 CL 170 105
500 AF 168 105
570 174 158
Rynite® PET 520 220
530 224
545 226
555 229
935 200
FR515 200
FR530 L, FR543 224
FR943 220
RE5211 S 227
RE5213 S 203
9082 F 251 232

8
 0,45 MPa 1,8 MPa
DAM DAM
Zytel® PA66 unreinforced E101 L, 101 F, E103 HSL 235 80
105 F BK-10 240 90
114 L BK-97 235 77
135 F 240 88
408 230 69
450, 490 225 65
ST801 219 66
Zytel® PA66 glass reinforced, FR70G28 V1 243
flame retardant FR70G25 V0 244
Zytel® PA66 glass reinforced 79G13 L 242
70G20 HSL, 70G25 HSL 254
70G30 HSL, 70G35 HSL 254
Zytel® PA66 mineral
reinforced, flame retardant FR70M30 V0 238 203
Minlon® PA66 mineral 10B140 240 210
reinforced 11C140 220 147
Zytel® PA66/6 unreinforced, FR7200 V0F 75
flame retardant
Zytel® PA66/6 glass FR72G25 V1 240 226
reinforced, flame retardant FR72G25 V0 215
Zytel® PA66/6 glass 72G15 L 215
reinforced 72G30 L 222
72G40 HSL BK* 224
Zytel® PA6 mineral and glass FR73GM50 GWF – 200
reinforced, flame retardant
Zytel® HTN HTN 51G35 HSL 276 264
high temperature nylon HTN 51G45 HSL 276 264
HTN FR51G35 L 270 255
Hytrel® thermoplastic polyester 7246 130 52
elastomer
Zenite® LCP liquid crystal 6130 WT-010 277 265
polymer 7130 WT-010 – 295
6330 WT-010 – 245
Vespel® polyimide resins SP-1, SP-21 360
* Only available in black.
For products or grades that do not appear on this table, please contact your DuPont representative for more information.
All the above information is subject to the disclaimer on the back page of this brochure.

9
Thermal Index - UL 746B measured at 0,8 mm

Electrical Mechanical Mechanical

with impact ºC without impact ºC
Crastin® PBT S600, S620 130 115 120
SK601 130 115 120
SK603 130 130 130
SK605 130 130 130
SK609 130 125 130
LW9130 140 125 140
LW9020 130 125 130
LW9030 130 125 130
T805 130 130 130
SO653 120 115 120
SO655 120 120 120
HTI619 130 125 130
S650 FR 130 130 130
SK642 FR 140 130 140
SK643 FR 140 130 140
SK645 FR 140 125 140
CE7931 130 130 140
LW9020 FR 140 115 120
LW9030 FR 140 125 130
T841 FR 130 120 130
T843 FR 130 120 130
T845 FR 140 130 140
HTI681 FR 140 130 140
HTI668 FR 125 125 125
HTI688 FR 125 125 130
Delrin® acetal 100*, 107*, 500*, 507* 50 50 50
100 ST* 50 50 50
500T* 50 50 50
500 CL* 50 50 50
500 AF* 50 50 50
570* 50 50 50
Rynite® PET 520 140 140 140
530 140 140 140
545 140 140 140
555 140 140 140
935 140 140 140
FR515 140 140 140
FR530 L 150 150 150
FR543, FR943 155 155 155
RE5211 S 140 140 140
RE5213 S 75 75 75

10
 Electrical Mechanical Mechanical
with impact ºC without impact ºC
Zytel® PA66 unreinforced E101 L, 101 F 130 75 85
E103 HSL 140 95 115
105F BK-10 125 65 65
135 F 135 75 85
450, 490 65 65 65
ST801 125 75 85
Zytel® PA66 glass reinforced 79G13 L 105 65 105
70G20 HSL, 70G25 HSL 105 65 105
70G30 HSL, 70G35 HSL 140 125 140
Zytel® PA66 mineral
reinforced, flame retardant FR70M30 V0 105 95 105
Zytel® PA66/6 unreinforced, FR7200 V0F 130 105 130
flame retardant
Zytel® PA66/6 glass reinforced, FR72G25 V1 115 95 95
flame retardant FR72G25 V0 140 120 140
Zytel® PA66/6 glass reinforced 72G30 L 105 65 105
Minlon® PA6 mineral 73M30 65 65 65
reinforced
Zytel® HTN HTN 51G35 HSL 150 125 130
high temperature nylon HTN 51G45 HSL 150 125 130
HTN FR51G35 L 140 120 130
Hytrel® thermoplastic polyester 5556 85
elastomer
Zenite® LCD liquid crystal 6130 WT-010 240 240 240
Polymer (1,5mm) 7130 WT-010 240 210 240
6330 WT-010 130 130 130

All the above information is subject to the disclaimer on the back page of this brochure.

* All Delrin® grades are measured at 1,5 mm.

11
For further information on Engineering Polymers contact:
Belgique / België Hellas Romania United Kingdom
Du Pont de Nemours (Belgium) Du Pont Agro Hellas S.A. Serviced by Interowa. Du Pont (U.K.) Limited
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Deutschland
Box 23 USA
Du Pont de Nemours DuPont Engineering Polymers
Norge S-164 93 Kista (Stockholm)
(Deutschland) GmbH Tel. +46 8-750 40 20 Barley Mill Plaza, Building #22
Distrupol Nordic
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Telex 410 676 DPD D Telefax 67 14 02 20 Du Pont Products S.A. Telefax (302) 892 0737
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Medgenco International Trade Co. Fürer-Haimendorf KG TR-80700 Istanbul should be sent to:
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Tel. (01) 512 35 71
Telex 93 742 MK UN Telex 112 993 IROWA A 2, chemin du Pavillon
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Du Pont de Nemours Geneva
512 35 71 31 Tel. (022) 717 51 11
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Polska Telefax (022) 717 52 00
Edificio L’Illa 3, Glazunova Street
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Avda. Diagonal 561 Kyiv 252042
ul. Prosta 69 Tel. (044) 294 9633 / 269 1302 http://www.dupont.com/
E-08029 Barcelona PL-00-838 Warszawa Telefax (044) 269 1181 enggpolymers/europe
Tel. (3) 227 60 00 Tel. (22) 635 04 01
Telefax (3) 227 62 00 Telefax (22) 691 09 00 The information provided in this documentation corresponds to our knowledge on the subject at the date
of its publication. This information may be subject to revision as new knowledge and experience becomes
available. The data provided fall within the normal range of product properties and relate only to the spe-
France Portugal cific material designated; these data may not be valid for such material used in combination with any other
Du Pont de Nemours (France) S.A. materials or additives or in any process, unless expressly indicated otherwise. The data provided should
ACENYL not be used to establish specification limits nor used alone as the basis of design; they are not intended
137, rue de l’Université Rua do Campo Alegre, 672 - 1o to substitute for any testing you may need to conduct to determine for yourself the suitability of a spe-
cific material for your particular purposes. Since DuPont cannot anticipate all variations in actual end-
F-75334 Paris Cedex 07 P-4100 Porto use conditions DuPont makes no warranties and assumes no liability in connection with any use of this
Tel. 01 45 50 65 50 Tel. (2) 69 24 25 / 69 26 64 information. Nothing in this publication is to be considered as a license to operate under or a recom-
mendation to infringe any patent rights.
Telex 206 772 dupon Telex 23 136 MACOL Caution: Do not use this product in medical applications involving permanent implantation in the human
Telefax 01 47 53 09 67 Telefax (2) 600 02 07 body. For other medical applications see “DuPont Medical Caution Statement ”, H-50102.

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DuPont Engineering
Polymers DuPont Engineering Polymers
12/98 Printed in Switzerland
H-11740 part II ® DuPont registered trademark