Electric Motor Insulation and Protection with Skived PTFE Films
Electric mobility is skyrocketing and electric motors are coming into focus for many applications, large and small. The global market for electric motors is projected to grow rapidly and along with that comes the need for stronger components to protect electric motors from damage. Engineers all over the world are working on innovative developments to solve the demand of various industries for electric motors with maximum performance, better durability and reduced costs to revolutionize future mobility.
Along with the demand for ever-increasing performance, the stress and loads on electric motors are also increasing, requiring strong components to protect the motor and its parts.
In this article let us find out how the superhero-like abilities of skived PTFE films can save the day and provide the necessary protection for your electric motors with Jan Kupzig, Application Engineer Films, Saint-Gobain® Tape Solutions. Discover how skived films can be the knight in shining armor for your electric motor insulation needs.
Skived PTFE films are ultra-thin materials that are manufactured from pressed and sintered resin billets rotating against a static knife. These films offer a unique combination of properties, including high temperature resistance, chemical inertness, low friction, and exceptional dielectric strength, making them ideal for demanding applications in harsh environments such as high-end electric motors.
Due to special surface activation processes, these non-stick skived PTFE films can be made bondable for facilitated use in food, medical, aerospace or industrial applications. These films combine various superpowers like outstanding material properties, ultra-thin thicknesses and the option to customize for specific application needs. They are unlike any other materials in this regard. That is why they can be considered as material superheroes.
Especially with the change in mobility to electric vehicles and the ever-increasing demand for maximum e-motor performance, skived PTFE films play an important role in protecting electric motor components. Let us dive deeper into how these small parts can impact electric motor design and performance.
Especially with the change in mobility to electric vehicles and the ever-increasing demand for maximum e-motor performance, skived PTFE films play an important role in protecting electric motor components. Let us dive deeper into how these small parts can impact electric motor design and performance.
Jan, what different types of damage can occur to an e-motor if not properly protected?
The key challenge is to avoid a short circuit in the electric motor. Nobody wants to see their car break down, least of all on a holiday trip, on the motorway or during an overtaking maneuver, where the engine must be relied upon. Accordingly, reliability and trust are essential for the use of our film.
In addition, a short circuit can cause everything from a defective fuse to engine damage to a fire. Thus, the film not only protects the car and its components, but also the driver and all passengers.
How can skived films provide the necessary protection and insulation for electric motors?
PTFE as a material is known for its very good insulating properties. In the case of electric motors, tracking resistance (Comparative Tracking Index, CTI) is particularly important. These are leakage currents that could flow from A to B on the surface of the foils and trigger a short circuit. Our PTFE films prevent these due to their outstanding insulation properties and in offering the highest CTI value of over 600V.
Jan, please tell us more about their use in high-performance electric motors.
Especially with high-performance motors, which are often operated with 800V, a high CTI is crucial. This is where the strengths of PTFE films come into their own and make it possible to combine safety and reliability with more performance and faster charging time. All over the world, engineers face the challenge of reducing the weight and size of high-end electric motors to achieve maximum power density. This results in increased stress for materials and components and the need for part protection and insulation under extreme conditions. Skived PTFE films can be the key to success for such high-end applications as in 800V motors due to their unparalleled combination of properties.
How can skived films be customized to meet specific e-motor insulation and protection needs?
Saint-Gobain Norgard™ Skived PTFE Films are customized products that can be adapted to customers’ or application requirements. This is possible, for example, by adjusting the film thickness to increase or reduce its insulation properties. The width of the film can also be adjusted directly for the process steps. The special surface activation technology used for our Norgard products is considered the best on the market, providing significant advantages over less performing Natrium-Naphthalene treatments.
The technology we use penetrates the deepest, lasts the longest, and brings the strongest surface activation. Other benefits from that technology are that the final products are odorless, and our etched PTFE film is also food-grade compliant and has received FDA and EU1935/2004 certifications in external laboratories.
— Jan Kupzig, Application Engineer Films
This surface activation allows PTFE films to be bondable to the customer’s materials for ideal performance of the laminate for customer-specific applications and tailored to their needs. For electric motor applications specifically, we work hand in hand with motor designers to understand their requirements and to push the limits of what is currently possible — together.
Next time you think you need a superhero to solve your toughest thermal, chemical, friction or electric insulation challenges, skived PTFE films may be the ones to call.
Their ultimate protection and insulation properties are designed to perform where other materials are beyond their limits. Contact our task force of tape experts today and see which specific product from our portfolio can become the savior for your electric motor insulation and protection projects.