functional epoxy coating powders for motor armature and stator insulation

SolEpoxy DK7-FamilyEpoxy Coating Powder for Coil Windings, MotorArmatures and Stators

Epoxy Insulating Coating Powders • Durable Dielectric Molding Compounds • Optoelectronic Compounds solepoxy.com2

Torque ManagementPower Closure

Adjustable Tilt Steering

ABS Motor

Engine Cooling Fan

Quality cars can have up to 130 motorsThe following are examples of brush motors

Sunroof Opening

Seat Adjustment(up to 4 per seat)

Window Lifts

Wiper Motor (2)Door Locks

(up to 6)

Epoxy Insulating Coating Powders • Durable Dielectric Molding Compounds • Optoelectronic Compounds solepoxy.com

(Hybrid) Electric VehicleTraction

Hybrid Electric Vehicle Battery Cooling

Oil Pump

Electric Brake

Quality cars can have up to 130 motorsThe following are examples of brushless motors

3

Electric Power Steering

Fuel Pump

Dual Clutch Transmission

Engine Cooling


Coil Winding InsulationWhy do we need it and how can we do it?

… a tried and proven method often used by companies making lower-end motors

An electric motor is made by wrapping an electric current around a magnetic core, and these two must be insulated from each other. This can be done in two ways.

Paper slot liners

Plastic case to

hold slot

liners

Using Slot Liners and Plastic Casing

… used by companies that can understand the efficiency and performance benefits.

Use Insulating Epoxy Coating Powder


Coil Winding Insulation: Paper Liners vs. EpoxyEpoxy Coating Powder improves reliability because it…

100%

Paper Slot Liner

Allows you to use up to 25% more copper wire

Provides a more even, consistent distribution

75%

… making your motor more efficient.

… which improves the balancing, efficiency and lifetime of your motor.

Is 10x more conductive than air

… which dissipates more heat from the motor, increasing

operating lifetime.

5

Air (25°C)Epoxy Coating

0

0.05

0.1

0.15

0.2

0.25

0.3


Motor Armature Insulation ClassesWhat are they and why do they matter?

DK15-0984

Insulation SystemClass

MaximumHot Spot

Temperature (°C)

A 105°C

B 130°C

F 155°C

H 180°C

The Rule of Thumb is that a 10°C rise cuts the insulation's useful life in half and a 10°C decrease doubles the insulation's life.

The motor’s insulation class is the maximum (hot spot) temperature at which the insulation can be operated and still have an average life of 20,000 hours.

Maximum Hot Spot Temperature =Ambient Temperature: (57°C) +Motor Temperature Rise (75°C) +Hot Spot Allowance (5 - 15°C) (15°C)

142°C Maximum Hot Spot Temperature

Motor Insulation Class Required: F

© 2009 Pedal Power Generators, LLC


SolEpoxy UL-Listed Coating PowdersProduct Tradename Category File Number

HYSOL DK15-02B HYSOL Epoxy Powder Coating (EP - Powder) E343402 HYSOL DK15-0463(d) HYSOL Epoxy Powder Coating (EP - Powder) E343402 HYSOL DK15EG-05 Black HYSOL Epoxy Powder Coating (EP - Powder) E343402 HYSOL DK15EG-05 Green HYSOL Epoxy Powder Coating (EP - Powder) E343402 HYSOL DK7-0953M HYSOL Epoxy Powder Coating (EP - Powder) E343402

Link to File Number E343402 can be found here:goo.gl/TQLHj5


For 95% of DC motors, Class B (130°C) is OK…but some applications require Class F (155°C) and even Class H (180°C)

Case Example 2:ABS Motor

- Big 58mm diameter motor - Class H insulation

Case Example 1:Power Closure Motor

- Powerful Motor -Class H insulation

Motors used in high continuous temperature environments may need Class F or H:

Below are typical automotive operating environments:On Engine or Transmission: 140°CAt the engine (intake manifold): 125°CUnderhood near engine: 120°CUnderhood in remote location: 105°CExterior, passenger compartment & elsewhere: 70°C – 80°C

SolEpoxy provides two of the best Class F materials and Class H material is under development.

Large, powerful or motors operating at high ambient temperatures may require Class H insulation.


Epoxy Coating Power Application MethodElectrostatic Fluidized Bed Blow Coating

… Industry standard for providing a thin, uniform coating thickness

… old technology that is less expensive, but orders of magnitude less consistent.

DK7-1000B*Only powder optimized for Blow Coating

*Currently sold as DK15-02B 60 mesh


Used by major tier 1 and 2 automotive manufacturers on millions of motors over the past 30 years.

Great Performance:High cut through resistance temperature (minimum 300°C)Excellent edge coverageHigh service temperatures and insulation classCapability to provide a range of thermal conductivitiesOutstanding chemical resistance, including motor oil & fuel

Great Manufacturing Productivity:Best-in-class shelf –life & bed-lifeHigh build rate enables faster coating line speedOutstanding adhesion to metal and plasticsLow thickness required to achieve max performanceBoth induction and oven cure chemistries

Epoxy Coating Powders for Coil WindingsAC and DC motor armatures and stators

Industrial motors include power tools, home appliances and industrial motors

SolEpoxy Coating PowdersIn automotive, motors are used for enclosures, windshield wipers, seat

adjusters, window lifts and fuel pumps


Industry Standard Color ChoicesBlack and Green are most common motor colors

Coil Windings Epoxy Coating Powders ProgressComplementary Product

Clear epoxy coating powder fixes and impregnates copper wires after winding

Incredibly Shelf-Stable ProductUp to 12 months shelf life @ 25C

High Thermal Conductivity (~0.9W/mK)For better heat dissipation

DK7-2300 Clear*Coil Fixing and Wire Impregnation Powder

DK7-2500 Black*Electric Vehicles and other applications requiring high

thermal conductivity*available to sample

11

“M” for Great Manufacturing ProductivityBest-in-class electrostatic pick-up & edge coverage

DK7-0953M Blue / GreyIdeal for fluidized beds in very warm, high humidity

climates, used for years in Mexico, India, South China & France

DK7-1000B Green*For older blow coating equipment

*formerly DK15-02B 60 mesh

Gasohol ResistantSolvent Resistance for Fuel Pump Applications

DK15EG-05 Black / Green*Developed for in-tank fuel pumps, Suitable for all Automotive Motors

and Small Motors where fuel and solvents may be present.*In our product family as DK7-2100 Black & Green

Two of the world’s best Class F materials

Next Generation Materials

Same Great Productivity + Class H Insulation ClassBest-in-class rating

DK7-3000 Black*Combines Class H formula with thermal conductivity technology

for larger, high-power motors*in development now

Uses old technology


Price

Epoxy Coating Powders for Coil WindingsRelative product family positioning

Performance

DK7-1000B*Blow Coatable

*DK15-02B 60 mesh

Class A Insulation SystemsTypically used for motors built before 1960s. All epoxy coating powders, by nature of their filler content meet this low 105°C standard.

DK7-3100Class H Capable

DK7-2500Thermally Conductive

Class F Insulation SystemIndustrial 5-10HP (3.7-7.5kW) motors or 25mm Class B motors with winding

temperatures up to 155°C

Class H Insulation SystemLarge, electric motors, or motors in a high ambient

operating temperature environment (underhood) with winding temperatures

up to 180°C

Epoxy Coating Color

Product Roadmap

DK7-3500Class H

Thermally Conductive

Slightly more expensive functional filler provides

superior electrostatic fluid bed productivity

Class B Insulation SystemSmaller motors, up to 5HP (3700W)

will have a maximum winding temperature of 130°C

DK7-0953MBlue & Grey DK15EG-05*

*In product family as DK7-2100*


Property Comparison Chart

Property / ProductDK7-0953MBlue & Grey

DK15EG-05**DK7-2100*

DK15-02B Mesh 60**DK7-1000B DK7-2500 DK7-2300

General Application Slot Insulation Slot Insulation Slot Insulation Slot Insulation Coil ImpregnationWire impregnation lIncredible Shelf-Life Stability,Shelf Life @ 25°C

l12 months

Stable bedlife in humid environmentUsed in India, Mexico and France l

High Thermal Conductivity l0.9 W/mK

Best in Class Edge Coverage l (46%)Gasoline / Gasahol resistance lUsed on production parts > 15 years l lBest UL 1446 Insulation Class Rating F (155°C) F (155°C)Blow Coating Process lElectrostatic Fluidized Bed Process l l l lVisual Inspection (defects easily seen) l l

Available colors S BlueS Grey

S BlackS Green

S BlackS Green S Brown S Black S Clear

Lowest cure conditions, minutes 45s @ 220°C 45s @ 220°C 45s @ 220°C 45s @ 220°C 45s @ 220°CBest Electrostatic PickupSpecific Gravity, g/cc

l1.68 g/cc

Highest Heat Resistance Cut Through Temperature, °C

l365°C

l380°C

Dielectric Strength, V/mil (kV/mm) 785 (31) 1010 (39) TBD 1100


SolEpoxy works on Braun Sondermachinen

Key Benefits:Fully Automated LinesWorld Leader in Electrostatic

Fluidized Bed for Motor ArmaturesRepeatable, consistent thickness

SolEpoxy DK7-0953M Light Blue*Epoxy Coating Powder for Coil Windings*Also available in Grey


DK7-0953M is used on automotive micro-motors manufactured in Mexico, India, China & France

Highest rate of electrostatic build – enhances productivity because coating lines can be set to run faster12-month shelf-life, extraordinary bed-life & low cure temperature makes this powder easy to use.Best-in-Class edge coverage – improves first-pass qualityLight blue or grey color enables easy visual inspection for hi-pot failure

SolEpoxy DK7-0953M - most productive powder*Part of the DK7-2000 Family


Competitor ADK7-0953M

DK15EG-05*

0

50

100

Gasohol Resistance, %

DK15EG-05 is Flex Fuel / Gasohol Resistant*In the product family as DK7-2100

Gasohol ResistantDK15EG-05 can and has been used in fuel

pumps in direct contact with fuel

DK15EG-05 is unique. It was developed for narrow slots, and gasohol resistance – two key properties for

fuel-pumps. Millions of assemblies are in use, submersed in (direct contact with) gasoline/gasohol.

Qualified to Spec. ESF-M3L72-A which includes sour gas containing highly corrosive hydrogen sulfide.

Gasohol and Solvent Resistant

*DK7-2100


Better edge coverage ensures that there is enough material at the hardest to coat parts of

the armature.

SolEpoxy Edge Coverage Comparison

Competitor A DK7-0953M DK15EG-050

10

20

30

40

50

Electrostatic Edge Coverage (%)

High Edge CoverageBetter edge coverage ensures that there is enough material to prevent shorting at the hardest to coat

parts of the armature.

*DK7-2100

minimum 120µ (40%)

300 – 400 µm


Competitor A DK7-0953M DK15EG-05

0

50

100

150

200

250

300

350

400

Cut Through Temperature (°C)

Cut Through Resistance Testing measures the temperature at which the epoxy no longer

provides strong mechanical separation from the coil winding

Minimum Automotive Requirement is 300°C

SolEpoxy Cut Through Resistance

High CT TemperatureBetter High Temperature Resistance

Cut Through Resistance Test

*DK7-2100


Inventory remains “in-spec” much longer, enabling SolEpoxy to offer Safety Stock and

Economical Supply Chain Service Worldwide.

DK7-0953M is also incredibly bed-stable in humid environments and is used in humid,

non-temperature controlled production facilities in Mexico, China, France and India.

Best-in-Class Shelf-Life & Bed StabilityDK7-0953M is perfect for hot, humid factory locations

Incredibly Shelf-Stable materials

Long Shelf & Bed LifeMost Motor Iron Powders Have Shelf Life < 6 Months

*DK7-2100

Competitor A Competitor B DK7-0953M DK15EG-05*

0

6

12

18Shelf Life @ 10°C, in months


Competitor ADK7-0953M

DK15EG-05

200

210

220

230

240

250

Lower Cure Temperature – Saves Energy

DK7-0953M and DK15EG-05 (DK7-2100) have recommended induction cure profiles of 45 secs @

220°C s as opposed to 45 secs @ 245°C for the most widely used motor iron powder coating.

Recommended Cure Temperature

Lower Cure TemperatureCuring temperatures 25oC lower than the

competition translates into a large energy savings when calculated on a yearly basis.

*DK7-2100


Great Shelf-life Enables Global Usage SolEpoxy Offers Safety Stock & Supply Chain Services

100 tons

120 tons

100 tons30 tons

7 Market Partners and 4* Regional Safety Stock Warehouses

Annual Deliveries in Metric Tons

functional epoxy coating powders for motor armature and stator insulation

Technology

c epoxy coating

epoxy epoxy coating

c solepoxy

c underhood

c rise

c exterior

c decrease

electric motor