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News Release
Primerless bonding of DuPont™ Zytel® nylon and
DuPont™ Vamac® AEM for integrated electronic
connector gasket
Photo: Courtesy of DANA corporation
A new electronic connector gasket from Dana integrates wiring harness, power
connectors and DuPont™ Zytel® and Vamac® polymers in a primerless bond, reducing
assembly time by 30-40% and component cost by 25-40% compared with conventional
gaskets and separate wiring harnesses.
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The use of the images (photos, slides, transparencies, etc.) granted by DuPont is authorised only in connection with the editorial material supplied by
DuPont itself and cannot be used to illustrate material related to products and/or services given by companies other than DuPont.
News Release
Primerless bonding of DuPont™ Zytel® nylon and
DuPont™ Vamac® AEM for integrated electronic
connector gasket
Photo: Courtesy of DANA corporation
This detail of the new Dana integrated electronic connector gasket shows elastomeric sealing
surfaces of Vamac® AEM (shown in blue) bonded permanently to rigid structural parts of
Zytel® PA66 nylon resin (shown in black) to provide oil and high temperature resistance, while
eliminating leak paths.
This image can be downloaded as a hi-resolution file at: / News from Businesses / Performance Polymers
News Release
Primerless bonding of DuPont™ Zytel® nylon and
DuPont™ Vamac® AEM for integrated electronic
connector gasket
Geneva, October 2011. A new electronic connector gasket from Dana Corporation of
Neu-Ulm, Germany, is one of the first applications to benefit from patented 2K molding
technology for the production of assemblies combining DuPont™ Vamac® ethylene
acrylic elastomer (AEM) with DuPont™ Zytel® nylon resin. The multi-shot technology,
licensed solely to DuPont by Evonik Degussa GmbH, allows the direct bonding of rubber
and plastics and simplifies assembly by eliminating the need for primer or anchoring. The
upshot of the new technology for first tier suppliers of integrated automotive components,
such as Dana Corporation, is the opportunity for greater cost and processing efficiencies
as well as enhanced part quality and reliability, even after heat and automotive fluid
In the case of the highly integrated connector gasket, which includes both a wiring
harness and power connectors, its seal made of Vamac® AEM is permanently bonded to
the gasket body of Zytel® nylon to provide long term heat and oil resistance and to
eliminate leakages. The particular grade of Zytel® nylon 6,6 specified for the gasket body
combines excellent mechanical properties with enhanced heat aging performance,
hydrolysis resistance and improved oil resistance. For its part, when used in seals,
Vamac® AEM provides high sealing performance, low permeability and excellent
resistance to oil and grease. Moreover, seals made of Vamac® AEM are highly resistant to
compression set and maintains long-term sealing force, meaning that the gasket can be
disassembled and reassembled again for reuse.
“The greatest challenge was to seal metals, thermoplastics and rubber materials at the
open window connector point. We worked closely with DuPont to modify the polymers
and develop new process technology to create optimal adhesion between Zytel® nylon and
Vamac® AEM throughout the gasket,” comments Berthold Schiele, sales engineer and
project manager for plastic systems at Dana. “The adhesion of Vamac® AEM to Zytel®
nylon exceeded our expectations. We subjected the bonded materials to a special pull
force test, but the extra force necessary to separate the two far exceeded the actual
News Release
operating conditions the gasket will meet in long-term service. Consequently, we can see
considerable potential application for this technology and materials combination in the
The Dana gasket is the first to integrate wiring harness, all fuel injector, plug, sensor and
actuator/solenoid power connections. The result is a highly-integrated unit, complete with
pre-assembled wiring harness that can reduce assembly time by 30-40%, and eliminates
the need to machine cylinder head holes, feed cables or control wiring direction. Thus,
accurate positioning of all power connections is assured, while yielding a 25-40%
component cost saving compared with conventional gaskets and separate wiring
In addition to undergoing a 150,000 mile in-vehicle endurance trial, the electronic
connector gasket has met or exceeded all industry standard tests, including heat aging, and
exposure to internal engine heat, oil and dynamic operating conditions. Its subsequent
adoption by major players in the off-highway, construction, agricultural, stationary and
marine diesel engine markets has been rapid. The first commercial installations in Europe
took place from early 2010 in large diesel engines manufactured by MTU, Deutz, and
Liebherr, following exhaustive validation and field trials.
DuPont Performance Polymers is committed to working with customers throughout the world to
develop new products, components and systems that help reduce dependence on fossil fuels and protect
people and the environment. With more than 40 manufacturing, development and research centers
throughout the world, DuPont Performance Polymers uses the industry’s broadest portfolio of plastics,
elastomers, renewably sourced polymers, filaments and high-performance parts and shapes to deliver costeffective solutions to customers in aerospace, automotive, consumer, electrical, electronic, industrial,
sporting goods and other diversified industries.
DuPont (NYSE: DD) has been bringing world-class science and engineering to the global marketplace in
the form of innovative products, materials, and services since 1802. The company believes that by
collaborating with customers, governments, NGOs, and thought leaders we can help find solutions to such
global challenges as providing enough healthy food for people everywhere, decreasing dependence on
fossil fuels, and protecting life and the environment. For additional information about DuPont and its
commitment to inclusive innovation, please visit
The DuPont Oval Logo, DuPont™, The miracles of science™ and all product names denoted with a ® are
registered trademarks or trademarks of E.I. du Pont de Nemours and Company or its affiliates.
News Release
Press contact (UK, Benelux, Scandinavia)
Andrew Wilkins
Tel.: +44 (0)1353 663350
Fax: +44 (0)1353 663350
Email: [email protected]
DuPont press contact
Rémi Daneyrole
Tel.: +41 (0)22 717 54 19
Fax: +41 (0)22 580 22 45