High performance polyamides for improved reliability and safety in next-generation USB

High-performance polyamides, Stanyl® and Stanyl® ForTii™, made by Royal DSM, have been approved by global producers for use in the next generation of USB Type-C connectors. DSM’s materials answer the need for improved levels of safety and reliability. The introduction of the USB Type-C connector is the result of the need to reduce electronic waste. Legislation in Europe, for example, is enforcing the use of a standardized charging interface, so that one charger and its associated cable can be used for multiple devices. As a result, the USB Type-C connector will be obligatory from 2017. Some electronics OEMs, including Apple and Google, have already launched equipment that incorporates Type-C ports. The Type-C connector overcomes an important draw-back that has traditionally been associated with USB. Until now, numerous different types of plugs and sockets have been available, so, for example, charging two different mobile phones often requires two different sets of chargers and cables. In addition, “in” and “out” connectors have different shapes. The new USB type-C standard is the first USB connector with reversible design allowing it to function perfectly whether you plug it in right-side up or upside down, Moreover, with wall thicknesses at only 25% of previous generation connectors, they are much smaller. With USB Type C connectors being so small, the performance properties of the materials used for their housings are especially critical. Stanyl (polyamide 46) and Stanyl ForTii (polyamide 4T) have high CTI (Comparative Tracking Index) ratings well above 400V, which are a measure of their ability to provide electrical insulation. Alternative materials show a short break during CTI testing, resulting in a serious performance and safety issue for the complete device when in use and exposed to particles, moisture, sweat or other pollution due to electrical tracking. DSM high performance polyamides offer an ideal balance of toughness and stiffness. Furthermore, the flame retardant additive systems that they incorporate to provide a UL 94 V-0 rating contain no halogens. In addition to ensuring high output rates, the excellent processability of Stanyl and Stanyl ForTii also provides connector designers with flexibility in component structure and tooling design. Stanyl and Stanyl ForTii can be used to produce connectors with wall thicknesses as thin as 0.12 mm and which still have the required high mechanical properties. Their high flow in combination with high weld-line strength ensure the required high pin pull-out strength—the force needed to pull metal contacts out of the housing—parts successfully pass durability tests that involve mating and unmating plugs and sockets more than 10,000 times. Further important advantages for DSM high performance polyamides in this application include their ability to withstand the very high temperatures used in lead-free reflow soldering processes used to assemble components on printed circuit boards, as well as their compatibility with ultrasonic welding (used for joining separate connector components together in some designs). They also have very good wear resistance which is essential to meet the high mating/unmating cycles of manufacturers.