Adhesives and Sealants For the Electric Motor Industry Matt Donelan Tim Holmes

Transcription

1 Adhesives and Sealants For the Electric Motor Industry 2017 Matt Donelan Tim Holmes

2 Meet Your Presenters MATT DONELAN Market Development Matt Donelan is a Market Development Director for Henkel North America based in Rocky Hill, Conn. His responsibilities cover the Electrical and Optical segments including Lighting, Harnesses, and Electric Motors. Matt has over 20 years of experience at Henkel in both marketing and product management positions. He also has design, test, and manufacturing engineering experience in the aerospace, optical, medical and electronics industries. Matt holds a Bachelor s Degree in Mechanical Engineering from The University of Connecticut and an MBA from the University of Hartford. matt.donelan@henkel.com 2 08/17/17

3 Meet Your Presenters Timothy E. Holmes Regional Application Engineer 3 08/17/17 Timothy Holmes is an Application Engineer for Henkel Corporation since 2014, and is located in Rocky Hill, CT. Timothy currently supports the greater Michigan, Ohio, Indiana and Kentucky and West Virginia areas focusing on general manufacturing OEM applications. Timothy also provides support for the electric motor market and Henkel hybrid adhesives throughout North America. In this role, Timothy provides the primary technical support via internal lab testing and customer facility line process integration for qualifying adhesive solutions to bond, seal, prime, coat, and pot numerous applications. Timothy received his Bachelor s Degree from The College of New Jersey (TCNJ) in Engineering Management Specialization in Mechanical Engineering.

4 Objectives / Key Learnings 1. Increase your knowledge of electric motor markets and trends 2. Understand the major types of applications for adhesives & sealants in electric motors a. Motor-specific applications & Tacking 3. Potting and Encapsulation b. adhesive & sealant applications & Thread sealing 4. bonding 5. & Cleaning Applications 3. Learn the Go-To products for these applications 4. Understand decision process for the Henkel product solutions for the ACH s listed 4 08/17/17

5 Introduction Direct current (DC) Motor Cutaway 5 08/17/17

6 Typical Applications Brushed DC Motor Henkel Technologies Potting and encapsulation bonding ( in Stator) Steel Core Lamination Threadsealing reinforcement bonding treatment 6 08/17/17

7 Contents 1. Electric motor applications and market overview 2. Typical applications and considerations for adhesive and sealant selection Features & Benefits of different technologies Adhesive Type Selection Considerations Go-To Products ACH 7 08/17/17

8 Content & Objectives Motor Types (DC and AC Motors) Basic Properties of Permanent s Sintered Ferrite Rare Earth s Plasto-magnets Process Considerations and Product Selection Application Case Histories 8 08/17/17

9 Features segments to rotor segments to housing Replaces traditional mechanical fastening High impact strength and temperature resistance Resists impact/vibration Prevents corrosion Adhesion to all magnetic materials Benefits Reduced cost of assembly and inventory Easier to automate Vibration/noise reduction Higher impact resistance Higher temperature resistance Prevent corrosion Will not chip magnet 9 08/17/17

10 bonding Some basic considerations Galvanized (e.g. nickel plated) magnets have limited adhesion properties! Recommendation to use Acrylics for bonding Sintered magnets are often protected from corrosion by oil impregnation. Even after cleaning this oil can migrate to the surface during heat cure (especially in coarse grain magnets) which affects the bonding strength Stamped stack of sheets which make up the laminated core should be free of process lubricants (stamping and/or cutting oil residues) for optimum adhesion Laser-cut steel sheets can (depending on the process) glaze the surface (high reduction of adhesion)! Recommendation is to use Acrylics with adhesion promoter The cure speed can increased by additonal heat for every adhesion system. If faster handling strength is required this could be an option /17/17

11 bonding Application Qualification Questions Substrates! Type of magnet, type of metal, plating or coating on metal, coatings or residues on magnets or metal, cleanliness, approximate weights and size / shape. Geometry! ID of motor housing or OD of rotor, length-width-thickness of arc-shaped magnets, # and location of magnets, gaps, and planned fixturing technique. Environment! Long term heat, humidity, harsh conditions, pressure, chemical exposure, vibration, shock, impact? Plus, what are the short term manufacturing process conditions? Post-assembly cleaning, immersion, spray, heat? What about packaging, storage, and shipping conditions? Production! How many parts? How much adhesive per part? How many seconds or minutes available for dispense? Calculated flow rate required? How many seconds or minutes of open time needed before assembly? How many seconds, minutes, or hours available for fixture cure after assembly? How many containers of adhesive per day or week? Planned mfg model? Note: Cure speed of many epoxy and acrylic adhesives can increased via additional heat /17/17

12 Standard Products Acrylics Loctite AA 334 Loctite SF 7387 Loctite SF 7380 Loctite AA 331 Loctite AA 326 Loctite SF 7649 Loctite A-671 1K-Epoxy Loctite EA 9432NA Loctite EA E-214HP 2K-Epoxy Loctite EA 1C-LV Loctite EA E-30CL High Temp resistance (177 C) toughness and strength Solvent based activator Solvent-less activator Acid free, Fast fixture, High Temp resistance (177 C) and toughness Fast fixture, general purpose Primer N Gap Filling, 2-part bead-on-bead mixing, fast fixture Very high strength, high temperature, impact-resistant, aluminum-filled paste Very high strength, impact-resistant, non-sag paste Medium viscosity, 20 minute open time, Moderate temp resistance (120 C) Purpose, 30 minute work life 12 08/17/17

13 Standard Products 2K MMA Loctite H4500 Loctite H8000 Cyanoacrylate Loctite 480 Loctite 435 Loctite 4090 Ultra fast metal & plastic bonder Good initial strength and performance on galvanized Excellent flexibility and impact resistance at low temperature High strength (slow) High strength (fast) Hybrid CA/Epoxy Up to 150 C resistance 13 08/17/17

14 Potting Features Encapsulation and insulation against environmental influences Protection of components against mechanical impact, vibration, thermal shock and dust Protection against contamination and corrosion Explosion protection Benefits Higher reliability / long product life Can dissipate heat Can be automated 14 08/17/17

15 Potting Application Qualification Questions Substrates! Type of metal or plastic housing to be filled? What is inside the housing to be potted? Are there any coatings or residues on these components? What is the approximate weight, size, and shape? Geometry! Actual dimensions of the housing, approximate volume to be filled, complexity of fill, planned filling technique. Environment! Long term heat, humidity, harsh conditions, pressure, chemical exposure, vibration, shock, impact? Flammability Rating? Thermal Conductivity? Plus, what are the short term manufacturing process conditions? Post-assembly cleaning, immersion, spray, heat? What about packaging, storage, and shipping conditions? Production! How many parts? How much adhesive per part? How many seconds or minutes available for dispense? Calculated flow rate required? How many seconds or minutes of open time desired? How many seconds, minutes, or hours available for gel time, set time, or fixture time? How many containers of adhesive per day or week? What is the planned mfg model? 15 08/17/17

16 Potting Adhesive Types 2K PUs and 2K Epoxies Economical solutions Room temperature curing with unlimited cure-through depths. Often used to pot large volumes. Epoxies generally better thermal and solvent resistance PUs generally lower in cost and have higher flexibility. 1K heat cure Epoxies Perform similarly to two-part epoxies Better adhesion to plastics Fully cured much faster Light curing acrylics and light curing silicones Normally used for shallow potting applications. Faster processing speeds, but at a higher volumetric cost /17/17

17 Potting Standard products 2K EP Loctite EA E-40EXP Loctite EA E-30CL Loctite EA 1C-LV Loctite PE 3142 / 3165 Explosion proof for motors in hazardous environments Purpose, 30 minute work life Medium viscosity, 20 minute open time, Moderate Temp resistance (120 C) Thermally conductive, low shrinkage Silicone Loctite SI K Silicone, UL 94 V-0 Loctite SI 5088/ K Silicone, RTV + UV Cyanoacrylate/UV Loctite K PU Loctite 3364 Quick / Gap filling in plastic 2K Urethane, UL 94V-0 Fast Cure 17 08/17/17

18 Potting Standard products 1K EP EO1016 Low Halogen, Low shrinkage Eccobond A High temperature resistance, good thermal shock resistance, low shrinkage 18 08/17/17

19 Potting - ACH Loctite E-40 EXP Status Targets UL-674 approval for safety against explosion risk required Substrates: Anodized aluminum ring / PU cables Adhesion to both cables and metal ring Low shrinkage and good adhesion avoids gaps and thus re work UL-674 tests Solutions Product: Loctite E-40 EXP Benefits Passes UL tests Low shrinkage = no rework Easy to use 2:1: no product waste; clean process 19 08/17/17

20 Features Unitizes wires/electrical components Resistance to high loads, e.g. centrifugal forces, high speed start-n-stop cycles Protects wires against fatigue fractures Excellent adhesion to metals and plastics Benefits Allows higher rotation speeds High performance coating, surpasses normal conventional treatments (wire enamels) Higher reliability / longer life expectancy 20 08/17/17

21 Adhesive Types 1K heat cure Epoxies Suitable for high-volume production Easy to process, Have excellent electrical properties Can normally be dispensed just prior to the varnish trickle dispense and heat cure process oven Can cure simultaneously with the varnish or epoxy coating, thus does not add any workin-process or time-to-manufacture to the process Equipment maintenance costs are very low 2K Epoxies ly used in work cells Room temperature cure 2K Silicones Offer flexibility and superior temperature resistance 21 08/17/17

22 Standard products EP Loctite EA 9432NA {heat cure} Loctite EA 3985 {heat cure} Loctite EA 9460 {2 part} UV-Acrylate Loctite AA 3103 Cyanoacrylate Loctite 3092 Loctite Tak Pak Silicone Loctite 5600 Very high strength, impact-resistant, aluminum filled paste High strength, tough, black, thixotropic paste High strength, tough, gray, thixotropic paste Versatile, medium viscosity acrylic Gap filling 10:1 mix ratio Loctite universal / fast 2 part, fast fixture, flexible, high temp resistant 22 08/17/17

23 Tacking Features Fixes wires and insulation during production Prevents wire breaks due to vibrations Benefits Increased reinforcement of wire ends and pigtails reduces metal fatigue and dust / dirt corrosion / erosion Higher reliability / long life 23 08/17/17

24 Tacking Standard Products CA Loctite 406 Loctite 401 Loctite 435 Loctite 3092 Loctite Tak Pak Loctite AA 352 Loctite 4305 for plastics / fast curing universal / fast curing impact / fast curing gap filling 10:1 mix ratio (CA + Activator) anaerobic + UV + Activator CA / UV 24 08/17/17

25 Solutions for Electric Motor Assembly Coil Positioning Situation Motor manufacturers often need quick, temporary wire tacking that holds small coils of wire in place during manufacturing operations. Customers need a simple, inexpensive material that adheres to a number of substrates including plastics, coated and painted metals and magnet wire Challenges Instant Adhesives can set up too quickly to allow corrections / adjustments Some adhesives have strong odors and can cause operator sensitivity Solutions Loctite SI 5970 RTV Silicone Parts can be used as received. No cleaning is necessary prior to dispensing Typically 2 small dots of adhesives are sufficient to tack the coils in place and provide very high immediate green strength The Henkel solution provides an adjustable temporary adhesive which is easy to dispense Silicone technology is very operator friendly and passes Health & Safety requirements Benefits Very low odor No Health & Safety concerns Long open time allows location adjustment with no premature curing out of desired position Easy manual or automated dispensing Cost effective Eliminate coils shifting during manufacturing 25 08/17/17

26 Core Technology for e-motor Features High mechanical strength even under dynamic loads Prevents fretting corrosion, galling and keyway backlash Eliminates localized assembly stresses Bearings to housing Bearings on shaft Armature to shaft Benefits Higher strength and performance with existing designs Better performance and reduced cost for new designs: Lighter weight Fewer components Reduced machine tolerances Higher reliability / long product life 26 08/17/17

27 Standard Products Anaerobic Products: ( Metals) AC motors DC Motors Loctite 648 Versatile, high strength and fast cure, oil tolerant Loctite 638 Versatile, high strength and gap fill oil tolerant Loctite 620 High temp resistance (220 C) Loctite 641 Controlled strength for easier disassembly Cyanoacrylate: ( plastics) Loctite 480 High strength (slow) Loctite 435 High strength (fast) Loctite 401 High temperature (120 C) 27 08/17/17

28 Solutions for Electric Motor Assembly Compounds Situation Challenges Commercial kitchen appliance manufacturers need long term reliability for mounting bearings into motor flange plates. Often these flange plates can be plastics or contain plastic inserts Reliability assurance for bearings can require press fits requiring tighter dimensional tolerances and heavier gauge metals Solutions Very thin metal plates provide minimal bonding area Plastic inserts can wear due to bearing micromovement Combinations of metals, metal finishes and platings can be difficult to bond, especially with thermal expansion and contraction Loctite 680 Anaerobic Compound Typical previous method involves press fitting bearing into plastic motor flange or insert Use of new generation Anaerobic Compounds is very effective on as-received parts, usually requiring no cleaning Plastic parts can be used with Anaerobic products by using primers such as Loctite 7090 Henkel Anaerobics applied with semi manual or fully automatic Rotospray system Benefits Allows use of lower cost plastic components Permanently bonds bearing into faceplate of motor Unitized bearing assembly eliminates costly motor warranty replacement from spun bearings Automated dispensing equipment insures repeatable process to assure motor quality 28 08/17/17

29 Features Replaces pre-formed gaskets Suitable for many flange configurations Excellent durability and chemical resistance High adhesion to flange surfaces Benefits Reduces inventory and machining costs More reliable sealing and clamp load Increases structural stiffness and reduces micro- movements Increased load transfer and reliability 29 08/17/17

30 Standard Products Anaerobic Loctite 518 Loctite 5188 Loctite 510 Silicone Loctite 5600 Loctite 5920 SMPs Teroson MS 939 FR Teroson MS 9399 purpose, good oil contamination tolerance Flexible, for Aluminum High Temp resistance (200 C) purpose, highly flexible for stamped metal purpose, high temperature Flame retardant Fast, two comp., dual cartridge 30 08/17/17

31 Solutions for Electric Motor Assembly Sealing Motor Housings Situation Modern electrical motors have stringent warranty requirements and often need to operate in harsh environments Sealed motors need protection from entry of dust particles and water and other liquids Challenges Various substrates including aluminum, cast metals, plastics Sufficient sealing of metal to metal contact flanges without a sealant or pre-made gasket Industry standard testing to IP Grade water and contaminant entry Solutions Loctite SI 5910 RTV Silicone Loctite SI 5910 is non-corrosive and often used as a potting material to seal all of the motors electrical connections RTV Silicones are 1-component, no mix, and have excellent open time and reworkability Parts can be used as received. No cleaning is necessary prior to dispensing Silicone technology is very operator friendly and passes Health & Safety requirements Benefits Permanently sealed to moisture or any outside contaminants RTV Silicones are very low odor No Health & Safety concerns Easy manual or automated dispensing Long open time allows several minutes to assemble Easy disassembly for repair or maintenance 31 08/17/17

32 Assembly screws Features Fills all voids to unitize threads Resistant to thermal cycling Seals threads and prevents corrosion Replaces traditional / mechanical fasteners Benefits Through bolts Prevents clamp load failures due to vibration, improper torque and thermal cycling Prevents air and fluid leaks through threads Reduces overall assembly and inventory costs 32 08/17/17

33 Standard products Anaerobic: Loctite 222 Low strength Loctite 243 Loctite 263 or 270 Loctite 290 Loctite 248 Loctite 268 Loctite 425 Purpose (medium strength) High Strength, permanent Wicking grade for post assembly Medium strength, stick form High strength, stick form For plastic screws 33 08/17/17

34 Threadsealing Features Threaded fittings Seals against humidity Seals against industrial liquids and gases Prevent corrosion Vibration resistant sealing Suitable for all threaded components Benefits Junction box plugs Sealing and locking Improved reliability/extended life expectancy Replaces seals and o-rings 34 08/17/17

35 Threadsealing Standard products Anaerobic Threaded fittings Loctite 565 Purpose, Controlled Strength, UL Approved Loctite 542 Fine threads (up to ¾ ) Loctite 577 Coarse threads (above ½ ) Junction box plugs Loctite 567 High temperature (400F), UL classified 35 08/17/17

36 Features Bracket to housing Bond support frame Joins and seals different materials Fills gaps, allows greater tolerances Vibration resistance and noise reduction Benefits Stator to housing Enables use of new and dissimilar materials Fewer parts, simplified design Seals and protects from corrosion Lower cost 36 08/17/17

37 Adhesive Types There is a wide variety of adhesives that can be used for general bonding applications Acrylics (two-step and 2K) & CAs Epoxies (1K and 2K) PUs (1K, 2K, PUR HM) SMPs and Silicones The key selection criteria involves, but is not limited to, the following adhesive properties Adhesion to substrates Fixture Cure speed Temperature/environmental resistance Cost Processing requirements (dispensing and curing) 37 08/17/17

38 Standard products Bracket to housing Bond support frame Stator to housing Two-step Acrylic Loctite AA 330 bonding Loctite AA 3525 Light cure EP Loctite EA 9432NA 1K, Very high strength, impact-resistant, aluminum-filled paste Loctite K, EP/CA hybrid EA E-30 CL 2K, Purpose, 30 minute worklife CA Loctite 3092 Fast/gap filling, 10:1 mix ratio 2K-Silicone Loctite SI part, fast fixture, flexible, high temp resistant 1K Silicone Loctite SI 5970 bonding SMP Teroson MS 9399 FR Flame retardant Teroson MS 935 UL V94-1,5 HB Reactive HM Technomelt PU 4663 Fast fixture, versatile 38 08/17/17

39 Solutions for Electric Motor Assembly Situation Small motor manufacturers often use plastic housings including difficult to bond low surface energy plastics like polypropylene or polyethylene Ability to accurately dispense small amounts with automated or semi-automated equipment Challenges Adhesive must work well on a range of plastic and metal materials Very high strength required. Different epoxies have ranges of rigidity / flexibility Some gap fill required up to 0.5 mm Solutions Loctite EA 9483 or EA E-05CL Epoxy with 770 Primer Typical application would involve parts being cleaned Fixture time in as little as 15 minutes with Loctite 7063, followed by priming with Loctite Full cure can be heat accelerated 770 primer Epoxy adhesive can be dispensed by hand from small cartridge guns or through larger benchtop systems Benefits Very high strength Can be used to augment slip fits or snap fits Ranges of viscosities, colors, open times allow great flexibility for manufacturing processes Easy manual or automated dispensing Cost effective 39 08/17/17

40 Applications Application Types Inter-process cleaners Metal Pre-treatment Parts cleaning Cleaning after cutting, stamping or pressing, simultaneously passivating steel, cast iron and aluminum work pieces. Pre-bonding surface cleaners Finished goods cleaning Metal Pretreatment Painted frames (housings) will use some form of MPT Improved paint adhesion and corrosion protection New generation cleaner coater solutions prior to painting based on zirconium oxide are commonly used for multimetal conversion (steel, zinc, aluminium, silumin, EG, HDG) Traditional iron phosphating when MPT lines are not suitable for new generation coatings (line construction) 40 08/17/17

41 Innovation in e-motors New Product Pipeline Hybrids general benefits Fast curing/fixture High adhesion on all substrates Environmental & Thermal Resistance Gap-Filling capability Hybrids offer potential applications in e-motor applications (CA/Methacrylate vs Epoxies & standard MMAs) High adhesion on passivated Rare Earth magnets Very fast fixture (esp. at elevated temperature) Excellent Impact Resistance Improved H&S over traditional acrylics (lower odor) (CA/Epoxy vs 5 minute 2k epoxies) Improved adhesion and rapid fixture Improved temperature resistance 41 08/17/17

42 Henkel Adhesive Resources Henkel adhesives.com The Adhesive Sourcebook Plastic, Rubber and Metal Guides Application assistance LOCTITE ( ) Over-the-phone assistance Technical Information Services team 8 a.m.-5 p.m. Eastern time In-person assistance Local Adhesive & Sealant Specialists Technical Customer Service department Testing services Process development 42 08/17/17

43 AG Equipment Resources Equipment Website equipment.loctite.com Technical Repository E-Commerce Product Information Equipment Services rental/ loaners, spare parts, calibrations, repairs, warranty and technical support, etc LOCTITE Equipment Sourcebook 43 08/17/17

44 Electrical Motor Information Resources na.henkel-adhesives.com Electric Motor Design Guide and Guide edisontechcenter.org Theory and design electrical-knowhow.com Designs and benefits /limitations Contacts: Matt Donelan Electrical and Optical Market Development Tim Holmes Application Engineering 44 08/17/17

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