New Electrical Connector Grease Breaks Synthetic Hydrocarbon Heat Barrier.

FAIRHAVEN, Mass. -- Nye Lubricants has broken the polyalphaolefin (PAO) heat barrier with its new lubricant for automotive electrical connectors, at a cost that's significantly less than silicone or fluorinated oils. PAO normally has a ceiling of around 125(degree)C for continuous heat exposure. Nye's new grease, RheoTemp(TM) 761G, performs well at 175(degree)C.

Nye partnered with one of the world's leading connector manufactures to develop RheoTemp 761G and ensure the new grease would meet real world demands. They started with a "wish list" of features that included a high temperature target of 150(degree)C, reduced insertion force and no significant increase in electrical resistance after ten cycles of mating and unmating. Maintaining the "good qualities" that make Nye's NyoGel(R) 760G such a widely used connector grease was also important. Wear protection had to remain virtually the same, as did material compatibility, low water washout, and low oil separation.

After 18 months of development the new lubricant emerged. PAO remained the main wear preventing ingredient. Alkylated naphthalene (AN), another synthetic hydrocarbon fluid, was added to produce a unique high-temperature synthetic hydrocarbon blend that gives RheoTemp 761G a continuous exposure heat ceiling of 175(degree)C, vs. 125(degree)C for a typical PAO.

To make the grease "slippery" enough to satisfy insertion force standards from the U.S. Council for Automotive Research (USCAR), a proprietary blend of ureas was used to thicken RheoTemp 761G. The maximum allowable insertion force has recently been reduced to about half of what was previously accepted. RheoTemp 761G tests show up to a 50% reduction in insertion force, compared to NyoGel 760G, depending on connector type, size and contact metal. Insertion force reduction is especially good on larger connecters, which are more common in late-model cars and are often the most difficult for autoworkers to mate. Reducing insertion force lessens the chance of worker injury from the repetitive labor.

The morphology of the urea molecule is what accounts for the reduction in insertion force because urea molecules easily "slip and slide" across each other. Their shape also prevents urea from burnishing itself into the contact, which could create electrical resistance over time. Tests show both greased and ungreased connectors have similar resistance values, even after repeated insertions.

During the last 15 years, NyoGel 760G has become a near-industry standard. It is specified by Ford, GM, DaimlerChrysler and five of the word's top ten automotive connector manufacturers. RheoTemp 761G delivers all the qualities of NyoGel 760G, plus it reduces insertion force and performs at temperatures up 175(degree)C.

ABOUT NYE: Nye Lubricants is an engineering company that seeks long-term partnerships with innovative companies that use high-quality synthetic lubricants and optical gels to increase the value of their products. Nye's synthetic lubricants and optical gels are specified in a full range of industries, including automotive, aerospace, appliance, aviation, electronics, medical instrumentation, office automation, paperboard manufacturing, photonics, semiconductor manufacturing, telecommunications, and textiles. Founded in 1844, Nye maintains regional engineering offices throughout the United States and a network of distributors in Africa, Asia, Australia, Europe, and South America.