Electric motors require unprecedented power density, and must operate in harsh environments.
Insulation failure causes over 30% of electric motor failures, mainly due to extreme heat or thermal constraints.
The insulation system's maximum permitted temperature is a limiting factor in designing traction motors.
Current resins are flawed, being marketed to function beyond their thermal limitations.
FAC Technology has created the market's most robust high-temperature electric motor resins.
A series of high-performance, resins for impregnation, encapsulation and potting of electric motors and power electronics. Our resins exhibit glass transition temperatures (Tg) up to 220°C. Our materials boasts unparalleled durability and crack resistance at this Tg level, enabling high-temperature motor operation without compromising various electrical and mechanical properties that typically degrade above the Tg.
Accelerated testing case-study
To truly challenge our resins, we subjected them to the most intense electrical machine environment we could find: an Electrodynamic Vibration Test System. These systems push electric coils to their limits through extreme and irregular temperature and mechanical loading cycles, as they shake various components—including automotive parts and other electric motors—to the point of destruction. The leading resin in use for these systems cracked and failed after just 20 hours of aggressive accelerated testing. In contrast, FAC Technology's REMI system endured for more than 3.5 times that duration, remaining in perfect condition. The test had to be terminated to avoid causing damage to other parts of the system. Since then, the company has remarked, "we will have to design a different test in order to get this resin to fail." FAC Technology is always working on the cutting edge of resin durability and endurance. If you're curious about how our resin systems can enhance your product's longevity, don't hesitate to reach out to us. We are a dedicated team of engineers, passionate about conducting rigorous, representative testing to uncover the key to true motor endurance, going beyond simply reporting data on spec sheets.
"...we will have to design a different test in order to get this resin to fail."
FAC Technology has a database of different materials suitable for application methods ranging from trickle impregnation to encapsulation and potting. For use in electric motors, power electronics and beyond. Two example materials are outlined below:
The problem with thermal class
Electrical Insulation Systems (EIS) are categorised into thermal classes based on temperature and temperature rise, as defined by NEMA, Underwriters Laboratories (UL), and IEC standards. Electrical Insulating Materials (EIM) used in these systems are individually tested and assigned a Temperature Index (TI). The TI represents the temperature in °C at which a specific property, such as mass loss or flexural strength, reaches an accepted level of deterioration after 20,000 hours. The glass transition temperature (Tg) is crucial when evaluating polymer materials for high-temperature applications. Tg indicates the thermo-mechanical performance of a polymer, marking the shift from a rigid state to a softer, more flexible state. This transition impacts the material's electrical and mechanical properties, potentially compromising its performance as an insulator. Competing epoxy systems may advertise high-temperature ratings, like 180°C, with a Tg of only 60°C. To achieve this rating, they may simply measure the weight loss of their material after ageing without considering the deterioration of the polymer's mechanical properties when aged above its Tg. We perform comprehensive mechanical testing after ageing, always including strength testing. Additionally, when operating above the polymer's Tg, electrical properties such as dielectric strength and partial discharge resistance can be significantly impaired, leading to a decline in insulating performance. FAC Technology has developed the most durable high-Tg insulating resins on the market. These systems allow you to operate below the cured resin's Tg for unmatched endurance. Our product range covers various temperatures, including two signature products at 190°C and 220°C.
Make certain you select insulation designed for real-world thermal challenges.