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Liquid Crystal Polymer Flows Into The Tiniest Of Mould Cavities

01 August 2004

DuPont's Zenite liquid crystal polymer (LCP) is currently being used by
the Swiss electrical products manufacturer, Sonceboz, to manufacture very
thin-walled coil bobbins for its 4000 Series torque motor. Thanks to its
high thermal resistance and good melt-flow characteristics, Zenite fills
the tool cavities completely, even though the bobbins have a wall
thickness of just 0.30mm. Sonceboz uses a 30% glass fibre reinforced
Zenite for this application, enabling it to take the stresses of the
winding operation.

The material is also used to over-mould the wound coils, its low melt
viscosity preventing winding displacement during the injection process.
As the over-mould functions as a housing for the stator, it also serves
as a plastic bearing for the rotor shaft. Thanks to its good sliding
properties, Zenite LCP was used as a replacement for the separate
bearings of PEEK and bronze.

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