March 2015 1

SynchronmotorenOSWALD ELEKTROMOTOREN GMBH

Adhesives for E-Motors

Contents

March 2015 2

1Bonding tasks

3DELO-ML

4DELO-DUOPOX/-PUR

5Casting compounds

2DELO-MONOPOX

Bonding tasks electric motors

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Stator to housing

Shaft bonding

Magnet bondingWire protection

Covering of solder joints

Securing of coil windings

DELO adhesives for …

High temperature applications (≥ 220 °C) DELOMONOPOX HT

Fast processes (light fixation < 10 sec) DELO-ML DB, DELO-DUALBOND

Massive components (large tolerances) DELO-DUOPOX, DELO-PUREncapsulation (high reliability) DELO-DUOPOX CR, DELOMONOPOX GE

Your application: Magnet bonding

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Buried magnets

Gap-filling> 250 µm

DELO-ML5327

Anaerobic curing

Temperature resistance

up to 200 °C

Fast fixation Heat-curing High temp.≥ 200 °CHigh impact

DELO-MLDB135, DB180,

DB154Anaerobic and

light curing

Fixation < 10 secwith DELOLUX

20 or 80

DELOMONOPOXMG063AD272

Heat-curing epoxy

Fast induction curing

DELOMONOPOXAD298

Heat-curing epoxy

High run resistance

during curing

DELOMONOPOXHT281

Heat-curing epoxy

High temp. stability up to 220 °C

High dielectric strength

DELO-DUOPOXAD840

DELO-PUR 96942-component

epoxy

Peel-resistant

RT-curing

DELOMONOPOXHT282

Heat-curing epoxy

High temp. stability up to 220 °C

Impact modified

Surface magnets

Your application: Stator to housing

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Gap-filling> 250 µm

DELO-ML5327

Anaerobic adhesive

Fast fixation by using an activator

Fast fixation High temp.≥ 200 °C High impact

DELO-MLDB135, DB180,

DB154Anaerobic and light curing adhesives

Light fixation < 10 sec with DELOLUX 80

DELOMONOPOXAD272

Heat-curing epoxy

Good flowability

DELO-DUOPOXAD840

2-component epoxy

Peel-resistant

RT-curing

DELO-MLUB160

Anaerobic adhesive

Fast fixation by using an activator

Your application: Shaft bonding

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Gap-filling> 250 µm

DELO-ML5327

Anaerobic curing

Temperature resistance

up to 200 °CFast fixation by

using an activator

Fast fixation High temp.≥ 200 °C High impact

DELO-MLDB135, DB154

Anaerobic and light curing

Light fixation < 10 sec with DELOLUX 80

DELOMONOPOXAD272

Heat-curing epoxy

Good flowability

DELO-DUOPOXAD840

2-component epoxy

Peel-resistant

RT-curing

DELOMONOPOX HT281

Heat-curing epoxy

Temperature stability up to 220 °C

High dielectric strength

DELOMONOPOX HT282

Heat-curing epoxy

Temperature stability up to 220 °C

Impact modified

Encapsulation & covering

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DELO-DUOPOX

CR7162C casting resin

heat-curing

Low CTE of37 ppm/K

DELO-DUOPOX

CR8442C casting resin

Curing can be accelerated by

heat

DELO-KATIOBOND

45952Light activated

Irradiation time ≤ 60 s with

DELOLUX 80

DELO-MONOPOX

GE7271C casting resin

heat-curing

Very low CTE of11 ppm/K

DELO-DUALBOND

AD761Dual-curinglight/heat

Irradiation time ≤ 30 s with

DELOLUX 80

DELO-DUALBOND

AD4950Dual-curing

light/humidity

Fast light curing< 10 s with

DELOLUX 80

DELO-DUALBOND

AD465Dual-curinglight/heat

Fast light curing< 4 s with

DELOLUX 80

Fast light fixation

High chemical resistance Low CTE RT-curing High flexibility

Moderate chemical resistance

DELO-MONOPOX

GE7851C casting resin

heat-curing

High run resistance

Low CTE of 22 ppm/K

Wire protection / covering of solder joints

Stator / coil encapsulation

Adhesive families

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DELOMONOPOX1-component heat curing

epoxy

DELO-ML

2C adhesives

DELO-DUOPOXDELO-PUR

Typical bonding tasks – DELOMONOPOX

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Stress type Requirements met by DELOMONOPOX

Abrupt starts and stops High impact resistance (no bandages)

Temperatures above +150 °C High temperature stability up to +220°C

Dissimilar CTE Flexibility

Magnets to rotors or slots

Magnet half shells or ring magnets to stator

Advantages – DELOMONOPOX

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Gap filling up to 2 mm possible High strength High impact resistance High resistance to chemicals and temperatures Good adhesion to various magnet materials

Adhesive selection DELOMONOPOX

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Advantages new DELOMONOPOX HT

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50 % higher temperature resistance than a comparable standard product Increased temperature range of use up to 220 °C

Case study: Electric motor

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Task Bonding of magnets (ferrite) into steel pipes (zinc-plated)

for electric motors, for example of wheelchairs

Components Steel pipe, black, zinc-plated Ferrite magnets

Selected adhesive DELOMONOPOX MG063 (tough-elastic)

Case study: Electric motor

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Required and tested adhesive properties Flexible, tough-elastic adhesive Magnet size (approx. 60 x 40 mm) and dissimilar

CTE of steel and ferrite One-component for easy processing Fast adhesive curing cycle time Temperature range of use up to +150 °C

Customer’s benefits Saving of time through automation of production (inductive curing) Increase in production volumes thanks to shorter cycle times (30 – 40 s)

Increased temperature requirements of +150 °C are fulfilled Increased strength requirements are fulfilled

Adhesive families

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DELOMONOPOX DELO-ML1-component anaerobic

adhesive

DELO-DUOPOXDELO-PUR

Magnets to rotors or slots

Magnet half shells or ring magnets to stator

Stator to housing

Typical bonding tasks – DELO-ML

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Stress type Requirements met by DELO-ML

Abrupt starts and stops High impact resistance

Temperatures above +150 °C High temperature stability up to +180°C

Dissimilar CTE Flexibility

Little gap filling is required (gaps ≤ 250 µm):

Shaft bonding

Advantages – DELO-ML

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Curing at room temperature (anaerobic + metal ions) Preliminary fixation with UV/ visible light, therefore short cycle times Tension-equalizing or flexible Storage at room temperature

DELO-ML 5327 UB160 DB133 DB135 DB154 DB180

Typical area of use Surface magnets Buried magnets Stator to housing Shaft bonding

Preliminary fixing with UV/visible light Accelerated curing with activator Flow behavior capillary to low-viscous

medium-viscous high-viscous

Tension-equalizing o o +++ ++ + ++Maximum temperature of use +200 °C +180 °C +120 °C +180 °C +180 °C +180 °C

o low + moderate ++ high +++ very high

Adhesive selection – DELO-ML

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5327 UB160 DB133 DB135 DB154 DB180

Special features of product also for oily surfaces also for oily surfaces very flexible and tension-equalizing tension-equalizing impact resistant tension-equalizing

very high temperature stability and resistance

up to 200 °C

high temperature stability and resistance

up to 180 °C

good adhesion to smooth surfaces

good adhesion to smooth surfaces

high temperature stability and resistance

up to 180 °C fluorescent

capillates well high-viscous low-viscous low-viscous medium-viscous high-viscous

Viscosity [mPas] 300 10,000 700 1,200 3,000 17,000

Tensile shear strength [MPa]at room temperature, Al/Al 11 8 12 13 13 13

Temperature stability [MPa]at +150 °C, shaft/hub steel 30 16 4 7 14 8,5

Tensile strength [MPa] not determinable not determinable 20 30 70 25

Elongation at tear [%] not determinable not determinable 130 30 4 40

Young’s modulus [MPa] not determinable not determinable 300 1,000 3,000 900

Dual curing

Curing time Preliminary fixation:5 s (UVA light)Preliminary fixation:2 s (UV/visible light)

Preliminary fixation:2 s (UV/visible light)

Preliminary fixation:2 s (UV/visible light)

Irradiation time: 25 s Irradiation time: 10 s Irradiation time: 6 s Irradiation time: 10 s

Firmness to touch:2 – 4 min

Firmness to touch:2 – 4 min

Firmness to touch:3 – 6 min

Firmness to touch:2 – 4 min

Firmness to touch:2 – 4 min

Firmness to touch:3 – 6 min

Final strength:24 h

Final strength:24 h

Final strength:24 h

Final strength:24 h

Final strength:24 h

Final strength:24 h

Temperature range of use [°C] -60 to +200 -60 to +180 -40 to +120 -60 to +180 -60 to +180 -60 to +180

accelerated curing possible with activator

accelerated curing possible with activator

New DELO-ML DB154

March 2015

Double temperature stabilityat 150 °C and 180 °C

Improved temperature resistance and stability up to 180 °C

0

5

10

15

20

25

30

35

40

45

initial valueat rt

100°C 150°C 180°C

Com

pres

sion

she

ar s

tren

gth

shaf

t/hub

ste

el

[MPa

]

test temperature

Temperature stabilityDB154 DB135

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Case study: Stator/housing

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Task Bonding of a stator to a housing

Component material Steel stator Aluminum housing

Selected adhesive DELO-ML DB135

(anaerobic curing and/or light curing)

Case study: Stator/housing

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Required and tested adhesive properties Tension-equalizing Flexible adhesive

(dissimilar CTEs of steel and aluminum) Fast firmness to touch in 60 s High extruding forces even at +150 °C Good adhesion to smooth metal surfaces Resistance to temperature changes (-40 °C to+120 °C)

Customer’s benefits Initial strength with activator within 60 s Production can continue quickly Improved strength in torque tests compared to the previously used adhesive Excellent adhesion to smooth metal surfaces One complex production step for roughening the surface is omitted

Section of the motorhousing – stator

©EBM-Papst

Process light fixation: Buried magnets video

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Adhesive families

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DELOMONOPOX DELO-MLDELO-DUOPOX

DELO-PUR2-component adhesives

Magnets to rotors or slots

Particularly suitable for large and massive components

Bonding tasks – DELO-DUOPOX / DELO-PUR

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Stress type Requirements met by DELO-DUOPOX / DELO-PUR

Abrupt starts and stops High impact resistance

Temperatures up to +130 °C Moderate temperature stability (otherwise DELOMONOPOX)

Dissimilar CTE Flexibility

Housing bonding

Magnets to stator

Securing of coil windings

Advantages – DELO-DUOPOX / DELO-PUR

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Particularly suitable for large and massive components Curing at room temperature (2C adhesive), can be accelerated by heat Gap-filling and tension-equalizing High peel resistance Storage at room temperature

Adhesive selection DELO-DUOPOX / DELO-PUR

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(UL File Number: E467212)

Case study: Wheelchair drive

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Task Wheelchair drive Bonding of segment magnets into a barrel

Component material Steel barrel, machined Pressed rare earth magnets

Selected adhesive DELO-PUR 9895

Case study: Wheelchair drive

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Required and tested adhesive properties Pasty viscosity allows dispensing onto vertical surfaces After adhesive application and joining, the components can be packed for shipping Reliable bonded connection even of components with dissimilar coefficients of

thermal expansion Temperature shock test: -40 °C to 90 °C Impact-resistant composite

Customer’s benefits Easy premixing of the 2C adhesive from the DELO-AUTOMIX double chamber

cartridge through a mixing tube Simple dispensing equipment with double chamber cartridge and pneumatic

extruding device The adhesive’s pot life of 30 min allows long processing times Support by adhesive manufacturer

Bonding tasks – Casting compounds

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Product group Properties/ Features

DELOMONOPOX GE 1-component heat curing epoxy with low CTE (11 ppm/K)

DELO-DUOPOX CR 2-component epoxy with high chemical resistance (e.g. gear oil)

DELO-DUALBOND/ -KATIOBOND 1-component light/ dual curing adhesives with high flexibility (light fixation < 10 sec)

Wire protection

Securing of coil windings

Covering of solder joints

Product overview casting compounds

March 2015 30

DELO-KATIOBOND

GE727 GE785 CR716 CR844 45952 AD4950 AD761 AD465

Typical area of use

Filler minerals minerals minerals minerals unfilled unfilled unfilled unfilled

Heat-curing Heat-curing 2C + heat-curing 2C at room temperature

Light activation Dual-curing light/humidity

Dual-curing light/heat

Dual-curing light/heat

o o o o ++ +++ ++ +++

o o o (+) ++ +++ +++ +++

+++ o ++ + ++ ++ +++ ++

+++ +++ +++ ++ + (+) + +

+180 °C +180 °C +180 °C +180 °C +150 °C +120 °C +150 °C +120 °C

o low + moderate ++ high +++ very high

Flowability

Low thermal expansion

Chemical resistance

Max. temperature of use

DELOMONOPOX

Curing mechanism

Curing speed

Flexibility

Stator/coil encapsulation

DELO-DUOPOX DELO-DUALBOND

Wire protection

Covering of solder joints

Case study: Vibration protection

March 2015 31

Task Vibration protection of the connecting wires of field packages for

power tools exposed to vibrations

Component material Connector terminal: PA 66 GF30 Wire: Copper-lacquered wire

Selected adhesive DELO-PUR 9694

© Copyright 2007 Metabowerke GmbH (Metabo)

Case study: Vibration protection

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Customer’s benefits Reliable protection of the field packages from wire fracture thanks to tough-

elastic adhesive behavior Easy and cost-efficient automation, integration into existing system possible

Required and tested adhesive properties Easy processing with DELO-AUTOMIX double

chamber cartridges Good adhesion to the materials used Pasty viscosity prevents the adhesive from flowing

away Further assembly steps are not influences

Permanent flexibility of the adhesive even after aging

Takeaways

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Short cycle times (light fixation < 10 sec)

High chemical and temperature resistance up to 220 °C

Tension-equalizing to very flexible

Very high impact resistance

Capillary to gap-filling

DELO supplies a powerful product range for bonding modern electric motors

Satisfied customers

March 2015 34

ANDREAS STIHL AG & Co. KG ● BSH Bosch und SiemensHausgeräte GmbH ● Continental Automotive GmbH ●ContiTemic microelectronic GmbH ● Daimler AG ● Diehl AKOStiftung & Co. KG ● DLR Dt. Forschungsanstalt für Luft- undRaumfahrt ● Duscholux AG ● ebm-papst GmbH & Co. KG ●Festo KG ● Honeywell AG ● Infineon Technologies AG ●Knowles Electronics Austria GmbH ● Miele & Cie. KG ● OSRAMOpto Semiconductors GmbH ● Recaro Aircraft Seating GmbH &Co.KG ● Robert Bosch GmbH ● Siemens AG A & D MC ●Sony ● TRW Airbag Systems GmbH ● Voith Turbo GmbH & Co.● ZF Electronics GmbH … and many more

Selection guide: E-motors - bonding

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Selection guide: E-motors - casting and coating

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General

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GeneralDELO ensures the quality of the adhesives with the help of the values specified.

The data and information provided are based on tests performed under laboratory conditions. Reliable information about the behavior of the product under practical conditions and its suitability for a specific purpose cannot be concluded from this.

It is the user’s responsibility to test the suitability of the product for the intended purpose by considering all specific requirements.

Type, physical and chemical properties of the materials to be processed with the product, as well as all actual influences occurring during transport, storage, processing and use, may cause deviations in the behavior of the product compared to its behavior under laboratory conditions.

All data provided are typical average values or uniquely determined parameters measured under laboratory conditions. The data and information provided are therefore no guarantee for specific product properties or the suitability of the product for a specific purpose. Verbal ancillary agreements are deemed not to exist.

This laboratory report, or data thereof, must not be forwarded to third parties without DELO’s prior written consent.

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