Major Applications of PPS Compounds

Automotive component applications represent the market segment where PPS will continue to experience significant growth. In addition to exhibiting excellent elevated temperature performance and chemical resistance (to gasoline, engine/transmission fluids), there exist cost reduction benefits associated with increased productivity through injection molding. In recent years, PPS has successfully replaced metal, aromatic nylons (PPA, 46 nylon), phenolic polymers and bulk molding compounds (BMC) in a wide variety of engineered vehicle components.
Due to the extensive DIC.PPS product portfolio, there exist products which will deliver the performance features required for even the most demanding component applications – ranging from the smallest electrical connector to the largest charge air cooler located under the hood of many globally produced vehicles. A wide range of DIC.PPS grades are used, in addition to the standard grades of glass fiber reinforced FZ-11XX & FZ-21XX Series and the FZ-36XX & FZ-66XX Series with excellent cost performance, the Z Series such as Super Tough Z-230 and Z-650 is expanding the application ranges due to its heat shock resistance, vibration and impact resistance required for automotive component parts.

■ Ignition coil casing, coil bobbins
■ Transistor ignition housings
■ IC regulators
■ Rectifier terminal blocks
■ Alternator brush holders
■ Fuse cases
■ Air conditioner hose clamps

■ Head light reflectors (projection type)
■ Bulb sockets

■ Fuel/intake air flow meters
■ Fuel pump impellers, housings
■ Throttle bodies
■ Throttle body valves
■ Exhaust gas control valves
■ Injector coil bobbins

■ ABS system hydraulic pistons
■ Transmission servo pistons

■ Hybrid vehicle inverter components
■ Pressure sensors
■ Speed sensors
■ Position sensors
■ ECU control unit housings (engine, power steering...)
■ Solenoid valve bodies

■ Thermostat housings
■ Coolant pump impellers, housings
■ Radiator upper, lower

PPS delivers elevated temperature performance, precision moldability, and dimensional stability to withstand the SMT process, along with the required UL94V-0 flame resistance without incorporating flame retardant additives. These characteristics make PPS an ideal injection molding product for use in producing electrical and electronic parts such as connectors, electronic control modules and sensors.
In general, FZ-1140 and FZ-2140 are primarily used because they balance the basic characteristics of PPS along with moldability. FZ-1140-D5, FZ-2140-D5, and FZ-1130-D5 low-halogen types are suitable for molded products with precise and complicated shapes such as connectors. The FZ-3600 and FZ-6600 Series highly filled with filler are suitable for optical pickup applications that demand dimensional stability and rigidity. The EC Series, capable of ultra-low pressure molding, is suitable for sealing microcoils and electronic components.

■ Micro switches
■ Capacitors
■ Photo interrupters
■ SMT-compatible connectors
■ Fiber optic connectors
■ Various coil bobbins
■ Transistor sealing
■ Hard disk actuator coil sealing

■ CD drive optical pickup bases
■ DVD drive optical pickup bases
■ Hard disk drive motor shaft bearings
■ Motor insulators
■ Button cell insulator gaskets
■ LCD projector housings

■ LCD projection TV lamp housings
■ Microwave parts
■ Electromagnetic cooker coil bases
■ Lamp sockets
■ Hair dryer nozzles
■ Steam iron parts

In Industrial applications, DIC.PPS Super Tough Z Series is widely used for plumbing applications represented by water heaters. This is because of PPS's hot water resistance and the Z Series characteristics of pressure resistance and ductility are suitable for this application. PPS is progressing as an alternative to metallic materials represented by existing brass and modified PPE.
In applications for precision instrument parts, the AMORVON W Series modified PPS with a small degree of crystallinity useful for dimensional precision is optimal. For applications that require sliding characteristics like gears and bearings, grades that excel in low friction and low wear like FZL, CZ, CZL, and WL are optimal.
For laser copier and printer applications, FZL, CZ, CZL, and WL with their useful sliding characteristics in gears and shaft bearings, while at the same time having the heat resistance of PPS that withstands heat fusing, are widely used.

■ Water heaters
　□ Pump casings, impellers
　□ Joints
　□ Valves
■ Water faucet fixings
■ General purpose small pump casings, impellers

■ Copiers, printers
　□ Drive gears
　□ Bearing holders
　□ Roll cases

■ Small gear pumps
■ Flowmeters
■ Watch movements