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A shift plate made of DuPont Zytel nylon has been selected by Daimler Chrysler, maintaining its vital functional properties while immersed in gear oil.
A flexible printed circuit based on the DuPont Pyralux system, connects the electronics with the magnetic valves and with various sensors and floats which are also mounted on the shift plate. The entire module was developed and is supplied by Siemens VDO Automotive AG, Regensburg. Geiger technik, of Garmisch-Partenkirchen, supplies the shift plate.
Zytel LM70G35 HSLX was identified as the optimal material for this demanding application. This heat-stabilized nylon 66, reinforced with 35 percent glass fibre, is claimed to have outstanding resistance to hot gear oil and all its aggressive additives. The resin’s combination of high stiffness and elasticity allows snap-fits to be integrally moulded into the part; it also meets Siemens VDO’s requirement for laser-printability.
Gerhard Lepsien, key account manager at Geiger technik, said: “We and DuPont were both involved in the module’s development from the beginning. This meant that, at an early design stage, we could influence decisions affecting processing methods and parameters, and we could match the tool optimally with the part. DuPont helped us with mould-filling simulations and warpage analyses when evaluating various gating systems. As a result, we can respect very close tolerances without any difficulty, even though the part is a very large one.”
A flexible printed circuit carries the signals and currents between the control electronics and the gear connector, the sensors and the peripherally arranged magnetic valves. The flexible circuit is based on a Pyralux carrier laminate which is made up of a DuPont Kapton polyimide film, a high-temperature acrylic adhesive and a copper film.
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