Electric motors are driving the transport revolution
Groundbreaking power densities and harsh operating conditions require a new approach to electric motors
Over 30% of electric motor failures stem from overheating insulation
These overheating problems are a major limiting factor in better motor design and performance
This problem is made worse by legacy thermal classes that overstate the high temperature performance of insulation
FAC Technology is solving the overheating problem with resins designed for maximum robustness at high-temperature.
This includes a series of high-performance resins for impregnation, encapsulation and potting of electric motors and power electronics. FAC Technology resins exhibit glass transition temperatures (Tg) up to 220°C. FAC Technology materials boast 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
"...we will have to design a different test in order to get this resin to fail."
IMV Europe, Executive Officer
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 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 development partner 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.
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:
FAC Tech 193-500
Tg 193 °C
<200 mPa s
FAC Tech 220-500
Tg 220 °C
260 - 370 mPa s
The problem with thermal class
Legacy insulation thermal classes designed for industrial motors are not suitable for modern electric drives. Electrical motor insulation systems are categorised into thermal classes based on the maximum temperature allowed. These traditional classes were defined by various international bodies conceived to regulate the industrial motor market. Every insulation material has a temperature region where it begins to 'soften’ known as the glass transition temperature (Tg). As a material softens it loses its strength and other vital mechanical and electrical properties such as stiffness, dielectric strength and partial discharge resistance. This is a problem for electric motors that heat up significantly during operation. Most 180 (H) Class motor insulation resins have a softening temperature well below 180°C. In other words they are assigned a ‘Thermal Class’ beyond their true capabilities. While other high-temperature resins do exist, they're largely unsuitable for motor applications due to their brittleness and lack of crack resistance. This forces manufacturers to choose between cracking and high temperature softening. FAC Technology materials have high Tgs and so do not soften until above the advertised thermal class temperature. Unlike other high-temperature resins, FAC Technology’s have been engineered for exceptional crack resistance and durability. FAC Technology resins do not soften and they do not readily crack.