Essex Magnet Wire Develops High-Temp Insulation for Motor Windings

A new, high-temperature insulation system for the windings of traction motors has been developed by Essex Magnet Wire at its MagForceX innovation center (pictured above) in Fort Wayne, IN. The new product targets motor windings for hybrid electric vehicles, plug-in hybrid electric vehicles, as well as electric vehicles.  

EnduroTemp 260+ is a thin, film insulation designed to withstand higher operating temperatures rated at 265 degrees Centigrade thermal endurance. The product can extend motor life and protects motors against deterioration created by the modern power electronics controlling them, says the company.  

Matthew Leach

Matthew Leach, vice president of innovation and head of the innovation center said that the product is the latest in the company’s line of developments for the EV market. “This is the very type of disruptive technology that we are looking to develop to help the magnet wire industry continue to evolve,” he said. “Being able to increase the temperature threshold without sacrificing performance – in fact, helping to increase it – is something that is very exciting for our team.”  

Technological advancements being made to increase the efficiency of electric driven vehicles as well as elevated performance requirements of the traction motors and generators is making deterioration exponentially more severe, explained Leach. Designers have been forced to utilize power electronic speed control with higher voltages and faster switching frequencies to drive the motors which puts severe stress on motor windings. The new insulation thrives in conditions where typical winding insulation utilized for standard motors will fail under similar conditions in only a few hours, he said.  

MagForceX team

The Essex innovation center has a dedicated team of scientists and engineers exploring technologies impacting magnet wire. Efforts involve testing and innovating thermosets, thermoplastics, and additives as well as focusing on conductor processing and fabrication processes.  

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