King-Size Bobbin Takes the Heat in Electric Car

Description
The built-in battery charger for the new electric-powered 'Th!nk' city car relies on a large bobbin molded from Rynite®. The bobbin is part of a transformer coil assembly in a fivestage charger that plugs into an ordinary 110 V alternating current outlet. The transformer coil converts the power supply to 72 V direct current for charging the vehicle battery.

The bobbin measures 5.5 in. high by 4.25 in. wide (140 by 108 mm). It holds both primary and secondary coil windings, which are separated by an insulating flange. The finished coil is placed in a water-tight cast aluminum housing.

Benefits
High-heat performance. Rynite® easily handles the transformer's temperature rise (DT) of 100°C (212°F) above ambient temperature during operation. The OEM's ambient temperature specfication runs from -20°C to +50°C (-4°F to +122°F).

Fast product development. DPI saved time and money in meeting UL requirements with a preapproved DuPont electrical insulation system meeting Class H (180°C) requirements under UL 1446 and IEC 62114.

Molding productivity. Rynite® readily fills the large mold's cavities, sets up quickly, and releases easily.

Materials Used
Rynite® meets rigorous requirements for dielectric and mechanical performance while assuring high molding yields.

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