Top 5 Insulation Solutions for Advancing Electric Motor Performance in 800 V Motors
As we continue shifting into a new era of transportation, where sustainability and electric mobility is at the forefront, we cannot ignore electric motors and their importance in ensuring increased energy efficiency and enhanced vehicle performance. With engineers pushing the limits of motor design by adapting from a 400 V architecture to an 800 V architecture, one cannot overlook materials that can stand up to the challenges of thermal management, mechanical durability and electrical insulation.
In addition to the higher operating voltages, modern-day e-motors have a set of non-negotiable criteria including compact design, the ability to withstand demanding environmental conditions, and superior chemical and electrical resistance. Materials such as high-performance tapes and skived PTFE films provide reliable insulation and can serve as go-to solutions for next-generation e-motors.
Let’s explore 5 ways skived films and electrical insulation tapes can help meet the challenging demands of 800 V motors and propel other advancements in e-motor technologies.
In this article
1. Enhancing mechanical & electrical resistance
While industrial motors operate continuously, motors used in electric mobility face repeated start-stop cycles, which means mechanical durability is critical. Insulation tapes can provide the necessary mechanical strength to handle these challenging conditions. For example, CHR® PS.25, manufactured from high-performance glass fiber reinforced polyester film with acrylic pressure sensitive adhesive, is especially suited for providing a reinforcing functionality within compact electric motors. In applications where mechanical integrity is essential, it offers superior tensile strength and adhesion together with excellent dielectric value.
Electric motors undergo voltage fluctuations as they accelerate and decelerate. These voltage spikes require products with corona resistance as well as the ability to withstand a range of breakdown voltage capabilities. When looking at electrical resistance, the backing material used for e-motor tape products plays an important role. For example, Polyimide (PI, Kapton®) / Polyethylene naphthalate (PEN) is the best option for electrical resistance. A second-place contender is Aramid Paper (eg., Nomex®) / PET (Polyethylene Terephthalate) and, finally, glass cloth would be a third choice, where it can perform sufficiently well, but not as well as Nomex or Kapton products.
CHR X.50 and 6601, for example, combine different backings to ensure high-performance, flexibility and conformability with outstanding dielectric and mechanical properties.
2. Chemical resistance in high-performance motors
High-performance 800 V electric motors operate in environments where exposure to oils, greases and lubricants is not uncommon. Therefore, ensuring chemical resistance is crucial for the reliability, durability and longevity of the motor. In these environments, silicone-based adhesives excel, providing superior resistance compared to rubber and acrylic adhesives.
A dependable choice for high-voltage motors is CHR K.30. This product is manufactured from high performance Teonex® (Polyethylene-naphthalate) film with silicone pressure sensitive adhesive. It has excellent dielectric properties and is specially designed for high-temperature electrical insulation applications. This product can effectively withstand harsh chemicals, making it a dependable choice for high-voltage motors requiring chemical resistance.
3. High dielectric strength
As electric motors move towards the 800-volt architectures, the need for materials with high dielectric strength increases. Because voltage fluctuations in these motors have greater intensity than in lower voltage systems, insulation materials need to be capable of withstanding greater stress without breakage. Products such as h-old® PX.50 have backings that are comprised of Polyimide (PI), known for dielectric properties. These PI backings make h-old PX. 50 a top contender for 800 V motors where management of electrical spikes and reliable performance are a necessity.
4. Electrical insulation
Without a doubt, in 800 V electric motors, managing high electrical stress is critical to maintaining performance and safety. Among the best solutions for insulation in high-stress environments are Norgard® Skived PTFE Films. With exceptional dielectric strength, low friction and chemical resistance, skived films help to ensure long-term reliability of high-performance motors.
In high performance motors, one thing that is crucial is a high Comparative Tracking Index, or CTI. The CTI measures the electrical breakdown or tracking of a material used for insulation. The higher the CTI, the better the insulation. PTFE films offer the highest CTI value. This high CTI value prevents leakage currents that can cause short circuits, making PTFE films a top choice for electrical insulation in demanding motor applications.
One other key thing to note is that Norgard Skived PTFE Films are odorless and certified for FDA and EU 1935/2004 compliance, making them suitable even for use in industries beyond automotive. However, in the context of 800 V motors, the strong bonding properties of surface-activated PTFE films help ensure the motor remains insulated and protected from potential electrical and mechanical failures.
5. Customized solutions
Specific material compatibility for e-motor applications can vary depending on the type of motor, the type of vehicle and OEM specifications. Custom-made tapes can address key mechanical, electrical and chemical stresses that are placed on the e-motor.
If a PI tape needs reinforcement of glass cloth for enhanced dielectric and mechanical strength or if a Nomex paper/ polyester film needs laminate coating on one side with a rubber thermosetting adhesive on the other to perform in high-temperature electrical applications, our team has to know-how, capability and expertise to make it happen.
Skived PTFE films could also be tailored to specific application requirements by adjusting thickness, width, and surface properties for optimized performance. These adjustments can impact the film’s insulation properties, either increasing or reducing them. Norgard Skived PTFE Films have surface activation technology. This state of the art technology offers deeper and more durable bonding than traditional treatments, making these products ideal solutions for long-term motor insulation.
As the automotive industry continues to embrace 800-volt motors, the demand for reliable, high-performance insulation cannot be ignored. High voltage motors require materials that can withstand increased electrical stress, mechanical wear and chemical exposure while maintaining long-term reliability and safety.
The insulation solutions outlined here such as mechanically durable PET and PEN tapes and customizable Norgard Skived Films are at the forefront of meeting these challenges. By addressing the unique demands of high-voltage systems, these materials not only protect e-motors but help them to operate at peak efficiency, ensuring a safer, more efficient future for electric mobility.
With engineering teams pushing the boundaries of motor performance, our team is eager to help you tackle your e-motor challenges and help improve performance with electrical insulation films and tapes. These advanced solutions combine optimal adhesives and perfect backing materials and allow for seamless process integration to help power the next generation of 800-volt motors and beyond.