Specialty Polymers for E-Motor Systems

Solvay-automotive-emobility-emotors

Solvay Specialty Polymers offer advanced  insulation properties which help OEMs meet the demands of reduced motor size and weight paired with increased operating voltage and temperatures.

Enhancing Power and Efficiency in E-Motors

Electric motors continue to push the design envelope with higher voltages, higher temperatures, and new cooling fluids. Polymeric materials must be able to maintain electrical and mechanical properties in these more aggressive environments. In addition to maintaining electrical properties, the polymer must be tough enough to support harsh bending operations during manufacturing, provide good abrasion and scratch resistance, and be resistant to the water/glycol-based coolants or ATF used for thermal management.

Application Requirements Specialty Polymer Solutions
Magnet wire

FR V0

Heat resistance from 160°C to 250°C

Electrical insulation

Good permittivity

Multiple shapes (round, rectangular…)

Torlon® HHPAI (enamel, up to 240°C)

KetaSpire® PEEK * (extrusion, over 240°C)

Slot liners and slot wedges 

FR V0

Heat resistance

Stiffness for assembly

Electrical insulation properties

Ajedium PEEK Films (extruded, thicknesses
from 0.05 mm  to 0.2 mm)

Xydar® LCP (injection molded)

Xencor™ LFT (wedges)

Connectors and busbars

FR V0

Heat resistance

CTI, dielectric strength

Ryton® PPS *

Amodel® PPA *

Cooling -Traditional 

 

 

 

Cooling - Immersion

Glycol resistance

Heat Resistance

Dimensional Stability

 

Heat Transfer

Chemically inert and compatible

Non flammable

Ryton® PPS *

Amodel® PPA *

 

 

Galden® PFPE


 
Lubrication

Long-lasting lubrication 

Non flammable

High dielectric properties

Chemically inert

Compatible with metals, elastomers, plastics

Fomblin® PFPE
Seals

Flexibility to -40°C

Property Retention at +175°C

Resistance to Lubricants/Greases

Good Friction & Wear

Tecnoflon® FKM

* Products manufactured using 100% renewable energy.

 

Magnet Wire

Historically, magnet wire insulation used solvent-based enamels like isocyanate PAI or PI. More recently, commercial applications are using KetaSpire® PEEK extruded onto the magnet wire instead of solvent-based dip coating. In addition to improving manufacturing efficiency, the extrusion process allows motor designers to optimize the thickness of the insulation layer, thereby increasing the slot fill. Optimized slot fill can increase torque and power and potentially downsize the motor to reduce its weight and volume. 

Solvay offers the most versatile polymers for different kinds of magnet wires

Solvay-automotive-emobility-emotors-magnet-wire-insulations

 

Slot Liners and Slot Wedges

In the quest for higher performing electric motors, thinner, higher performing slot liners are needed to save space, improve slot fill, and optimize heat transfer. Just a single layer of Ajedium™ PEEK film can save space while also enabling superior heat transfer, thereby significantly outperforming laminate materials, increasing power and performance.

Solvay-automotive-emotors-slot-liners-slot-wedges

As an alternative to films, slot liners can be injection molded. Xydar® LCP is particularly suited for this application because of its exceptional flow through long path lengths and thin walls. Xydar® LCP displays excellent thermal conductivity along with high dielectric strength performance over a wide temperature range, it is inherently flame retardant and chemically resistant. 

Slot wedges help to hold windings into the stator slot. The Xencor™ LFT compounds are designed specifically to achieve maximum synergy between high performance, design freedom, function integration, weight reduction, and per-part cost economy through fast cycle times.

 

Connectors and Busbars

Amodel® PPA and Ryton® PPS are the primary materials to consider for high-voltage connectors and busbars. Amodel® PPA offers an excellent comparative tracking index (CTI) as well as high dielectric performance. Ryton® PPS offers enhanced retention of electrical properties after heat and fluid exposure. Our specialty polymers are optimized for thermal cycle performance with excellent chemical resistance and outstanding dimensional stability.

 

Lubrication and Cooling

As the industry moves toward integration of the e-motor into electric drive units, there will be increased emphasis on cooling and lubrication within these systems. 

Direct liquid cooling is the most effective way to dissipate heat in an electric motor and is becoming an emerging trend in this application space. Galden® PFPE fluorinated fluids provide good dielectric properties, exceptional chemical stability, and the capacity to perform at a wide range of operating temperatures.

Fomblin® PFPE fluorinated fluids provide excellent lubrication over a wide temperature range and they are engineered to give high performance in demanding applications where heat, chemicals, solvents, corrosion, toxicity, flammability, and service life present lubrication problems.

Solvay-automotive-emobility-emotors-service-temperature-range-graph

 

Seals

Seals need to be able to withstand greater friction and wear due to motors running at higher speeds.

Tecnoflon® FKM are highly resilient synthetic rubbers that retain critical properties in chemically aggressive environments at extreme temperatures. Tecnoflon® FKM can not only stand up to these high heat conditions but can also remain flexible at low temperatures and they are designed with superior friction and wear properties and higher heat capability than AEM/ACM.