hyundai product and technology fair solutions for hev - · pdf filehyundai product and...

Hyundai Product and Technology FairSolutions for HEV - MotorsHyundai / Kia R&D Center - June 27 th, 2006

Raimund PillathStefan SeifertJohnny YeoSteven SW Lee

Group EA 3 / 4 / 5"Environment –

Alternate Energy / Power"

2Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006

Solutions for HEV - Motors

Electrical Insulation Systems ( EIS )• Wire Enamels (WE)

• Impregnating Resins (IR)

• Core Sheet Varnishes (CSV)

Where are we locatedOur headquarters for business responsibility and R & D are located in Germany and in Austria

EIS belongs to BU: DuPontDuPont Performance Performance CoatingsCoatings


Solutions for HEV - MotorsDuPont - Five Growth Platforms

DuPont Safety &

Protection

DuPont Electronic &

Communication Technologies

DuPont Coatings & Color

Technologies

DuPont Performance

Materials

DuPont Agriculture &

Nutrition

Market Leadership

Large Opportunities Strong

Capabilities



Wuppertal

Nanjing

Brazil

Canada

Mexico

Austria

DPC Production CenterLicencees

Tollmanufacturer

NagoyaShanghai

Locations Electrical Insulation Systems ( EIS )

DuPont’s Electrical Insulation Systems are available everywhere in the world.We can supply globally and offer local service.

Headquarters and R & D Centers

Service and application labs in China (Shanghai), Mexicoand Japan (Nagoya) (DKK Automotive Center)

Jiangyin



Paint and Exterior

DuPont AutomotiveThis is how you know us …today



Materials for Chassis and Structural

DuPont AutomotiveThis is how you know us …today



Materials for Under Hood Components

Electrical Insulation Systems for Electrical Motors• Wire Enamels• Impregnating Resins• Core Sheet Varnishes

DuPont AutomotiveThis is how our customers know us …today



Battery - Ni-Me-H system- Li-Ion system- Ultra-Capacitors

Inverter / Converter- DC-AC Inverter- DC-DC Converter

Electric Motor- Engine Starter - Drive to Wheel- Charge to Battery

Generator

ECU - Electronic Control Unit

for each system

Hybrid Electric Vehicle: Unique Systems



Battery• Ionic liquids, electrolyte, binder• Membranes• Housing: Engineering Polymers

Inverter / Converter• Engineering Polymers

for housings, electrical transformer, new cooling system

• Electronic Materials

Generator & Electric Motor• Magnet Wires (Wire Enamels)• Impregnating materials• Insulation materials• High temp. eng. Polymers

Electronic Control Unit• Housing: Eng. Polymers• Polymeric film for Insulation• FCM, MCM

Opportunities for Material Solutions from DuPont



Solutions for HEV - MotorsSolutions for HEV - Motors

DuPontDuPont Materials in a MotorMaterials in a Motor

Vespel®

Delrin® (POM) Zytel® (PA)

Crastin® (PBT)

Zenite®

Teonex® (PEN)

Teflon®

Crastin®

Nomex®

Kapton® (CR) Vespel® (PI)

Voltron®

Wire Enamel

Voltatex®

Core Sheet Varnish

Impregnating Resin


Solutions for HEV - MotorsSolutions for HEV - Motors

Purpose of Wire Enamels• Primary Insulation of Round or Rectangular

Copper or Aluminum Wires



0,4 0,3 *)

> 1000> 900 *)

297

55 *)120

54 *)2 1 *)

0,0

100,0

200,0

300,0

400,0

500,0

600,0

700,0

800,0

900,0

1000,0

1100,0

Lifetime of different Magnet Wires under Inverter DutyLi

fetim

e [h

]

Standard, PEI+ AI Voltron™ Coating 1 Coating 2 Coating 3*) magnet wire with 10% pre- stretching ; coatings 1, 2 and 3 are pigmented insulation films

• VoltronTM E 3597 is a new generation of magnet wireinsulation that solves the problem of premature failures of inverter fed motors

Value for Hyundai Motor Company⇒ VoltronTM magnet wires for HEV - MotorsValue for Hyundai Motor Company⇒ VoltronTM magnet wires for HEV - Motors



-1500

-1000

-500

0

500

1000

1500

-0,002 -0,0015 -0,001 -0,0005 0 0,0005 0,001 0,0015 0,002

Time [s]

Volta

ge [V

]

Voltage at the motor

Corona inception at +/- 850 V

Voltage vs. Time at the Input of an Inverter Driven Electrical Motor



Benefits when using VoltronTM magnet wire• outstanding corona resistance

• prevent premature failures caused by partial discharges

• very high V-t Lifetime (more than 1000 hrs @ 2,4 kV)

• superior thermal properties under the influence of ATF – oil

• good flexibility

• high increase of film hardness

• use of nanotechnology ( no classical fillers )



Purpose of Impregnating Resins• Mechanical Strengthening of the Winding

• Additional Electrical Insulation

• Protection against Chemical and Mechanical Attack

• Improved Heat Transfer



Graph shows excellent emission behavior compared to conventional styrene-based products

0

200

400

600

800

1000

1200

0 20 40 60 80 100 120 140 160 180Curing Time (min)

Emis

sion

s (p

pm -

calc

ulat

ed a

s C

H 4)

UP-Impregnating Resinstyrene-basedE 4011, LP1006 lowemission

Comparison of Emissions 1K-Impregnating Resins: styrene-based / low emission systems

Value for Hyundai Motor Company⇒ low emission 1K-Impregnating Resins

E 4011 UV & LP 1006 UV

Value for Hyundai Motor Company⇒ low emission 1K-Impregnating Resins

E 4011 UV & LP 1006 UV



Aging Performance: comparison between conventional systems & new developed products shows excellent Bond Strength

M agne t Wire : Impreg. R e s in: Standard: IEC 61033

100 windings/ 0,315mm/twisted 720° Curing conditions date: 17.03.2006

Conditions for impre g.: Twisted Coil 10 min horizontal dipping - 10 min horizontal draining - Curing 4h in horizontal position at 150°C

Twiste d Coil:

Decrease of Bond Strength on Twisted Coils at 155°C after Aging at 260°CS H Therm 210 Grd 1 se e lege nd

4h 150°C

30

50

70

90

110

130

150

170

190

210

230

250

270

290

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70Aging Time (days)

Bon

d St

reng

th (N

)

conventional Styrene-based Impregnating Resin

E 4011

LP 1006



What‘s so special about Electrical-UV ?

Value for Hyundai Motor Company⇒ Herberts® Electrical / UV - ProcessValue for Hyundai Motor Company⇒ Herberts® Electrical / UV - Process

State of The Art Impregnating Technology

• most environmental-friendly impregnating-technology

• amount of resin usage and impreg-nating quality can be controlledexactly from average to maximum

• draining losses and evaporationlosses are minimized

• combined with low emission productsand high pre-heat temperaturesemissions from 1-3 % only are possible



Value for Hyundai Motor Company⇒ Herberts® Electrical / UV - Process

(for Impregnation of Stators)

Value for Hyundai Motor Company⇒ Herberts® Electrical / UV - Process

(for Impregnation of Stators)

0

20

40

60

80

100

Cos

ts (%

)

Plant Energy ProcessingTime

Cleaning ReductionVOC

Typical Dip & Bake Process Electrical / UV Process



Purpose & Users of Core Sheet Varnishes• Purpose:

electrical insulation of each metal sheet to another for construction of magnetizable cores in electrical machines

• Users:Producers of electrical steel and big-sized generators,worldwide

• VOLTATEX®:DuPont brand name for the family of highly sophisticated core sheet varnishes



Value for Hyundai Motor Company⇒ VOLTATEX® E 1175W:Value for Hyundai Motor Company⇒ VOLTATEX® E 1175W:

Properties5 excellent 0 not applicable

DuPont has developed the self-bonding varnish VOLTATEX® E 1175W, a waterborne system with excellent insulation and processing characteristics.These advantages make VOLTATEX® E 1175W the ideal insulation system for high performance applications, e.g. advanced HEV- Motors.

012345

Insulation

Punching

Overcoatability

Corrosion

Pressure StabilityBurnoff repair

Annealing

Welding

Bonding



Benefits when using Core Sheet VarnishVoltatex® E 1175W• Functional self-bonding varnish to hold a stack of electrical steel

sheets together and form a solid core

• Exact stack dimensions and flexibility in design

• homogeneous core stacking and no interlaminar cross-circuit in the stack

• No squeezing effect

• Excellent surface insulation

• High bond strength

• Waterborne system, environment-friendly, innovative varnish systems



• VOLTATEX® E 1120:the innovative Titanate based C5 insulation system with high heatresistance as an environmental-friendly alternative to delicate chromiumbased varnishes (complies with the stringent RoHS standards)

• VOLTATEX® E 1175W:self-bonding varnish system based on epoxy resins allowing a very efficient fixing technology for core sheet stacks

• VOLTATEX® E 1151:pigmented and filled core sheet varnishes engineered especially for the advanced generator industry

• VOLTATEX® E 1153:unfilled systems with excellent punching performance and outstanding resistance against mechanical and chemical influences

=> all VOLTATEX® systems are waterborne systems

Product Range VOLTATEX®: The Family of Core Sheet Varnishes



From Electrical Steel To Electrical Machinesyellow Requirements of Core Sheet Varnishes

Electrical Steel

Application

Compound Technologies

Punching

Annealing

Electrical Machines

GeneratorMotor Transformer

CorrosionInsulation

Al die castingStacking Welding Bonding



Impregnating Materials Wire Enamels Core Sheet Varnishes

DuPont Performance Coatings Electrical Insulation Systems

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