Multiple bonds in e-motors. Adhesives for E-Motors

Transcription

1 Adhesives for E-Motors Multiple bonds in e-motors

2 Magnet bonding Shaft bonding Bonding the stator to the housing Adhesives for e-motors DELO s adhesives for FAST PROCESSES (LIGHT FIXATION < 10 S) DB, DELO DUALBOND When manufacturing modern e-motors, it is essential to improve the efficiency, for example by minimizing the air gap between magnet and winding. Since conventional methods, such as mechanical clamping or wrapping reach their limits due to high tolerances, bonding is the solution. The requirements imposed on the e-motor components to be joined (and therefore also on the adhesives used) are high. In this respect, recurring buzz words such as temperatureresistant, resistant to chemicals, gap-filling, impact-resistant and tension-equalizing are often used. The adhesives specially developed for e-motors have precisely these properties. The overview on the left shows a selection of DELO adhesives used in specific e-motor applications according to their properties. HIGHLY RELIABLE CASTING DELO-DUOPOX CR, GE HIGH TOLERANCES, GAP-FILLING DELO-DUOPOX, DELO-PUR HIGH-TEMPERATURE APPLICATIONS (+220 C) HT CR = Casting Resin DB = Dual Bonding GE = General Encapsulant HT = High 2

3 Bonding magnets into housings Bonding magnets to rotors Bonding buried magnets into rotors Magnet bonding More and more e-motor magnets are bonded as adhesives have several property and process advantages over conventional mechanical joints: Tolerance compensation Evenly distributed stress Easy to automate Reduced vibration noise Good corrosion protection No component damage during joining Your benefits High temperature stability up to +220 C Excellent chemical resistance Good gap filling Fast light fixation (< 10 s) Tension-equalizing Find the right adhesive FAST FIXATION IMPACT- RESISTANT GAP-FILLING > 250 µm HIGH TEMPERATURE STABILITY +200 C DB135 DB180 DB DELO-DUOPOX AD840 DELO-PUR 9694 MG063 HT282 AD298 HT281 anaerobic / light Fixation in less than 10 s with DELOLUX 20 or Anaerobic curing resistance up to +200 C Fast fixation with activator 2C adhesives Peel resistance Fast induction curing Impact resistance High run resistance during curing High dielectric strength ROOM TEMPERATURE CURING HEAT CURING AD = ADhesive DB = Dual Bonding HT = High MG = MONOPOX Gießharz [casting resin] 3

4 Brushless DC motor ebm-papst Bond stator to housing Bonding the stator laminations to the housing is more advantageous than conventionally joining these components by pressing or shrinking: Equalize tensions between the stator and housing with dissimilar CTEs Heat not mandatory More cost-efficient production Improved acoustics by damping properties of the adhesive Larger production tolerances possible Your benefits High temperature stability up to +200 C Fast light fixation for short cycle times ( DB) Accelerated curing with activator () Curing at room temperature (except for ) Find the right adhesive FAST FIXATION HIGH TEMPERATURE STABILITY +200 C IMPACT- RESISTANT GAP-FILLING > 250 µm DB135 DB180 DB UB160 DELO-DUOPOX AD840 AD066 anaerobic / light Fixation in less than 10 s with Anaerobic curing Fast fixation with activator Anaerobic curing Fast fixation with activator 2C epoxy Peel resistance Good flow behavior ROOM TEMPERATURE CURING HEAT CURING 4 AD = ADhesive DB = Dual Bonding UB = Universal Bonding

5 Collector to shaft with DELOMONOPOX HT281 metabo Shaft bonding Similar to shaft-to-hub bonds in mechanical engineering, the shaft of e-motors is bonded to the bearing, rotor package and commutator. Anaerobic, low-viscous adhesives are preferred as the bonding gap is narrower due to very low tolerances. Adhesive bonds have the following advantages over classical form- or force-closed joints: Your benefits Fast fixation by activator or light () Curing at room temperature (, DELO-DUOPOX) Very high temperature stability up to +220 C () Low component production costs Easy to automate No clearance, no slip No friction or contact corrosion Find the right adhesive FAST FIXATION HIGH TEMPERATURE STABILITY +200 C IMPACT- RESISTANT GAP-FILLING > 250 µm DB135 DB DELO-DUOPOX AD840 AD066 HT282 HT281 anaerobic / light Fixation in less than 10 s with Anaerobic curing resistance up to +200 C Fast fixation with activator 2C epoxy Peel resistance Good flow behavior stability up to +220 C Impact resistance stability up to +220 C High dielectric strength ROOM TEMPERATURE CURING HEAT CURING AD = ADhesive DB = Dual Bonding HT = High 5

6 Motor for power tools Stator of an automotive drive module Partial protection of the windings Protection of the stator windings Contact protection Cast & cover Casting compounds are used in e-motors to protect sensitive components from humidity, chemicals or mechanical stress. Therefore, DELO s adhesives are used in the automotive industry due to these special challenges. Possible applications: Secure coil wires against vibration Cover soldered and welded contacts to protect them against corrosion Partial protection of windings from abrasive substances Stator casting Your benefits Excellent resistance to aggressive substances (e. g. gear oil) Outstanding thermal resistance and low thermal expansion combine to minimize tensions between cast and component Very fast fixation or curing by light Find the right adhesive HIGH RELIABILITY LOW CTE FAST FIXATION HIGH FLEXIBILITY DELO-DUOPOX CR844 DELO KATIOBOND DELO DUALBOND AD4950 GE727 DELO- DUOPOX CR716 GE785 DELO DUALBOND AD761 DELO DUALBOND AD465 2C casting resin Curing can be accelerated by heat Light-activated Irradiation time of 60 s or less with light / humidity Fast light curing in less than 10 s with 1C casting resin CTE 11 ppm / K 2C casting resin CTE 37 ppm / K 1C casting resin High run resistance CTE 22 ppm / K light / heat Irradiation time of 30 s or less with light / heat Fast light curing in less than 4 s with ROOM TEMPERATURE CURING HEAT CURING 6 AD = ADhesive CR = Casting Resin GE = General Encapsulant

7 Lab expertise DELO is a technology leader, generating about 30 percent of its sales revenues with products developed in the last three years. In addition, 15 percent of revenues are invested in the research and development of adhesives and associated equipment. These statistics are a result of the enormous laboratory expertise in the Windach headquarters: Comprehensive IDEA DESIGN PROTOTYPE ADDITIONAL BONDING TASKS analytics and lab tests make it possible to find the right adhesive for every bonding task, including those in e-motor bonding. In addition to chemical-physical characterization of adhesives, life cycle tests, application-specific test methods and process simulations are performed. INTEGRATION PRODUCTION ONGOING SUPPORT A COMPREHENSIVE OVERVIEW of pretreatment methods can be found in the BOND it Reference Book on Bonding Technology. Connectors: Reliable pin sealing Relays: Pin casting the adhesive flows into the cavity Microswitches: Pin sealing, bonding of housing, sealing of switch button Fast sealing of electronic components within just seco nds DELO s light-curing of microswitches adhesives enable the reliable sealing, relays and electronic components, connectors, fixing of and bonding Applications of housing parts. in the require fast bonding automotive industry in processes combining particular time with reliable short cycle process control. DELO s light-curing DELO-PHOTOB adhesives are excellent for this purpose: within seconds Fast curing by exposure to light ( curing enables immediate on demand ) in-line quality component control. This defects is necessary remedial can be detected promptly how actions can and cost. be taken, saving and time OND DELO-D UALBO Fast light fi xation within seconds (immediate final strength) DELO-PHOTO ND 1C acrylates Highly flexible and Curing in shadowedtension-equalizing areas (by heat or humidity) DELO-DUALB OND GE4906 GE4707 2,200 1,500 UV-VIS / humidity UV-VIS / heat to +150 C BOND Viscosity [mpas] GE4009 Curing 1,600 GmbH Minimum curing time [s] Elongation at tear [%] resistance Eltec DELO-KATIOBO UV-VIS ND DELO-D UALBO Viscosity [mpas] Curing sulatio d encap n-boar n RAFI Fast light fi xation within seconds Can be preactivated 1) (for opaque components) Chip-o Minimum irradiation time [s] Elongation at tear [%] resistance nts psula Enca h Reliability with Hig ND 1C epoxies Curing in shadowed areas (by heat) Hard or flexible composite DELO-KATIOB OND DELO-DUALB OND KB554 AD761 GE731 1,500 11,000 17,000 UV-VIS 1) UV-VIS / heat UV-VIS / heat to +150 C AD = ADhesive 40 to +180 C GE = General Encapsulant KB = KatioBond ,400 UV-VIS 1) 15 3 Encapsulants with High Reliability Sealing Electronic Components E-MOTOR PROCESS VIDEO DELOadhesives 7

8 CONTACT Headquarters Germany Windach / Munich Phone info@delo.de USA Sudbury / Boston, MA Phone usa@delo-adhesives.com Singapore Phone singapore@delo-adhesives.com China Shanghai Phone china@delo-adhesives.com Taiwan Taipei Phone taiwan@delo-adhesives.com Malaysia Kuala Lumpur Phone malaysia@delo-adhesives.com South Korea Seoul Phone korea@delo-adhesives.com 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. Nothing contained herein shall be construed to indicate the non-existence of any relevant patents or to constitute a permission, encouragement or recommendation to practice any development covered by any patents, without permission of the owner of this patent. All products provided by DELO are subject to DELO s General Terms of Business. Verbal ancillary agreements are deemed not to exist. DELO This brochure including any and all parts is protected by copyright. Any use not expressly permitted by the Urheberrechtsgesetz (German Copyright Act) shall require DELO s written consent. This shall apply without limitation to reproductions, duplications, disseminations, adaptations, trans lations and microfilms as well as to the recording, processing, duplication and/or dissemination by electronic means. 04/16 Adhesives Dispensing Curing Consulting