Motor Encapsulation | The Best Solution for Thermal Conductivity of Electric Vehicle Drive

The motor potting adopts thermal conductive materials, providing an effective solution for protecting and dissipating the heat of the electric vehicle drive system. This method not only protects electronic components from environmental pressure, but also improves overall heat transfer, ensuring smoother operation and longer lifespan of your electric vehicle. Below, Yilian will delve into the reasons why thermal management is crucial for electric vehicle motors, the advantages of using thermal conductive potting materials, and explore leading products in the market and future trends in electric vehicle thermal management.
1. Why thermal management is crucial for electric vehicle motors ↩ ︎
2. The benefits of using thermal conductive motor sealant ↩ ︎
3. Which material is most suitable for sealing electric motors? ↩ ︎
4. Recommended Sealing Materials for Yilian Motors ↩ ︎

Potting of motor stator
1.Why is thermal management crucial for electric vehicle motors?

For a long time, motor designers have been facing the challenge of thermal management in motor design. Without proper thermal management, heat loss can greatly reduce power efficiency, lower motor performance, and lead to premature component failure. Overheating not only affects overall performance, but also leads to insulation breakdown, demagnetization, and damage to sensitive electronic devices, greatly shortening the service life of the motor.
With the increasing demand for motors with higher voltage and power density driven by electrification, effective thermal management has become crucial. Appropriate thermal management can minimize power loss (I ² R loss), improve performance, and ensure reliability and efficiency.
With the increasing demand for electric vehicles, people’s expectations for range, charging time, and charging infrastructure are also growing. New designs typically use smaller components and higher power output, resulting in increased heat generation. This trend has driven the demand for advanced resins with excellent thermal performance to meet constantly changing demands.
2. The benefits of using thermal conductive motor potting compound
From a historical perspective, coating the rotor and stator windings with varnish has been a common practice for basic insulation. These varnishes are mainly used as initial protective layers, but due to their solvent based nature, they contain high concentrations of volatile organic compounds (VOCs), causing environmental problems. In addition, the design of varnish does not have high mechanical strength and often cannot meet the requirements of high-voltage electric vehicle motors, as high-voltage electric vehicle motors require enhanced electrical insulation and mechanical strength. High voltage motors require materials that can withstand vibrations, impacts, and thermal cycles while maintaining excellent dielectric properties – basic varnish is difficult to meet these requirements.
This has led to a transformation of the guide heat sealing material, which has several main advantages:
Comprehensive protection: The motor sealing material can form a sturdy barrier to resist environmental factors such as moisture, dust, and chemicals, ensuring that motor components maintain their functionality and reliability under harsh conditions.
Electrical insulation: The electric motor is sealed to fill the gaps inside the motor, preventing air pockets that may cause partial discharge and ensuring optimal electrical insulation, which is crucial for safe high-voltage operation.
Heat dissipation: High thermal conductivity potting materials can effectively transfer heat from key components, prevent overheating and maintain motor performance, while extending its service life.
Reduce noise, vibration, and harshness (NVH): Encapsulation materials for electric vehicle motors help to reduce vibration and noise levels, making electric vehicle motors run quieter and smoother, thereby enhancing the overall driving experience.
3. Which material is most suitable for sealing electric motors? three
Organic silicon potting
Silicone is one of the earliest sealing materials used in electric vehicle motors because of its low viscosity, making it easy to flow even in complex components. A silicone sealing material with a thermal conductivity of approximately 3 W/mK can effectively dissipate heat.
However, its inherent flexibility and high coefficient of thermal expansion (CTE) may cause problems at high temperatures. The expansion of silicone at high temperatures can generate mechanical stress, which may cause delamination or cracking of encapsulated components. In addition, silicone is relatively soft and elastic, so it cannot provide sufficient mechanical stability, making it less suitable for applications that require high structural integrity, such as those involving high vibration environments in electric vehicle motors.
Polyurethane (PU) potting
Although PU resins are flexible and easy to process, their glass transition temperature (Tg) is relatively low, typically ranging from 60 ° C to 120 ° C, which limits their thermal stability in high-voltage motors. The polyurethane bond of PU is prone to hydrolysis and degradation at high temperatures, thereby reducing its dielectric properties and heat resistance. In addition, the high coefficient of thermal expansion (CTE) of PU can cause significant stress in the material, leading to delamination and impaired adhesion under high temperature and vibration.
Epoxy resin potting
Due to the limitations of silicone and polyurethane, epoxy encapsulation materials have become the preferred choice for high-voltage electric vehicle motor applications due to their following characteristics:
High glass transition temperature (Tg): Epoxy resin can maintain its structural integrity even at high temperatures, making it an ideal choice for the harsh thermal conditions of electric vehicle motors.
Excellent mechanical strength: Epoxy resin has a highly cross-linked polymer network with excellent mechanical properties, which can effectively resist vibration, impact, and thermal cycling. This ensures strong protection for motor components throughout the entire operating life.
Enhanced chemical resistance: Epoxy resin has strong resistance to various corrosive chemicals, including coolant and oil commonly found in electric and hybrid vehicles. This chemical stability ensures long-term reliability and performance.
These characteristics make epoxy resin an ideal choice for high-voltage motors, balancing performance, protection, and durability.
4.Recommended Potting Materials for Elaplus Motors Potting Compound

If you need to learn more about product information, you can obtain it from the following ways:
◇ Send an email to info@elaplus.cc Email address;

◇ Call the hotline 021-67227200 for consultation;

◇ Directly contact ELAPLUS sales personnel and various distributors to obtain;

Tags: Stator Encapsulation · Organic Silicon Encapsulation compound · Thermal Management · Epoxy Encapsulation compound · Motor Stator Encapsulation · Motor Encapsulation · Polyurethane Encapsulation compound

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