Hyundai Product and Technology Fair Solutions for HEV - Motors Hyundai / Kia R&D Center - June 27 th, 2006 Raimund Pillath Stefan Seifert Johnny Yeo Steven SW Lee Group EA 3 / 4 / 5 "Environment Alternate Energy / Power"
Electrical Insulation Systems ( EIS ) Wire Enamels (WE) Impregnating Resins (IR) Core Sheet Varnishes (CSV) EIS belongs to BU: DuPont Performance Coatings Where are we located Our headquarters for business responsibility and R & D are located in Germany and in Austria 2
DuPont - Five Growth Platforms DuPont Safety & Protection DuPont Electronic & Communication Technologies DuPont Coatings & Color Technologies DuPont Performance Materials DuPont Agriculture & Nutrition Large Opportunities Strong Capabilities Market Leadership 3
Locations Electrical Insulation Systems ( EIS ) Wuppertal Austria Canada Jiangyin Nagoya Nanjing Shanghai Mexico DPC Production Center Headquarters and R & D Centers Licencees Service and application labs in China (Shanghai), Mexico Tollmanufacturer and Japan (Nagoya) (DKK Automotive Center) DuPont s Electrical Insulation Systems are available everywhere in the world. 4 We Junecan 27-2006 supply globally and offer local service. Brazil
DuPont Automotive This is how you know us today Paint and Exterior 5
DuPont Automotive This is how you know us today Materials for Chassis and Structural 6
DuPont Automotive This is how our customers know us today Materials for Under Hood Components Electrical Insulation Systems for Electrical Motors Wire Enamels Impregnating Resins Core Sheet Varnishes 7
Hybrid Electric Vehicle: Unique Systems Generator Battery - Ni-Me-H system - Li-Ion system - Ultra-Capacitors Inverter / Converter - DC-AC Inverter - DC-DC Converter ECU - Electronic Control Unit for each system Electric Motor - Engine Starter - Drive to Wheel - Charge to Battery 8
Opportunities for Material Solutions from DuPont Generator & Electric Motor Magnet Wires (Wire Enamels) Impregnating materials Insulation materials High temp. eng. Polymers Battery Ionic liquids, electrolyte, binder Membranes Housing: Engineering Polymers Electronic Control Unit Housing: Eng. Polymers Polymeric film for Insulation FCM, MCM Inverter / Converter Engineering Polymers for housings, electrical transformer, new cooling system Electronic Materials 9
DuPont Materials in a Motor Vespel Kapton (CR) Nomex Voltatex Core Sheet Varnish Teflon Crastin (PBT) Vespel (PI) Teonex (PEN) Voltron Wire Enamel Zenite Crastin Impregnating Resin Zytel (PA) Delrin (POM) 10
Purpose of Wire Enamels Primary Insulation of Round or Rectangular Copper or Aluminum Wires 11
Value for Hyundai Motor Company Voltron TM TM magnet wires for HEV - Motors Lifetime of different Magnet Wires under Inverter Duty Lifetime [h] 1100,0 1000,0 900,0 800,0 700,0 600,0 500,0 > 1000 > 900 *) 400,0 297 300,0 200,0 120 55 *) 54 *) 100,0 0,4 0,3 *) 2 1 *) 0,0 Standard, PEI+ AI Voltron Coating 1 Coating 2 Coating 3 *) magnet wire with 10% pre- stretching ; coatings 1, 2 and 3 are pigmented insulation films Voltron TM E 3597 is a new generation of magnet wire insulation that solves the problem of premature failures of inverter fed motors 12
1500 1000 Voltage [V] 500 0-0,002-0,0015-0,001-0,0005 0 0,0005 0,001 0,0015 0,002-500 -1000-1500 Time [s] Voltage at the motor Corona inception at +/- 850 V Voltage vs. Time at the Input of an Inverter Driven Electrical Motor 13
Benefits when using Voltron TM magnet wire outstanding corona resistance prevent premature failures caused by partial discharges very high V-t Lifetime (more than 1000 hrs @ 2,4 kv) superior thermal properties under the influence of ATF oil good flexibility high increase of film hardness use of nanotechnology ( no classical fillers ) 14
Purpose of Impregnating Resins Mechanical Strengthening of the Winding Additional Electrical Insulation Protection against Chemical and Mechanical Attack Improved Heat Transfer 15
Value for Hyundai Motor Company low emission 1K-Impregnating Resins E 4011 UV & LP 1006 UV Comparison of Emissions 1K-Impregnating Resins: styrene-based / low emission systems Emissions (ppm - calculated as CH 4) 1200 1000 800 600 400 200 0 UP-Impregnating Resin styrene-based E 4011, LP1006 low emission 0 20 40 60 80 100 120 140 160 180 Curing Time (min) Graph shows excellent emission behavior compared to conventional styrene-based products 16
Decrease of Bond Strength on Twisted Coils at 155 C after Aging at 260 C M agnet Wire: SH Therm 210 Grd 1 Impreg. Resin: see legend Standard: IEC 61033 Twisted Coil: 100 windings/ 0,315mm/twisted 720 Curing conditions 4h 150 C date: 17.03.2006 Conditions for impreg.: Twisted Coil 10 min horizontal dipping - 10 min horizontal draining - Curing 4h in horizontal position at 150 C Bond Strength (N) 290 270 250 230 210 190 170 150 130 110 90 conventional Styrene-based Impregnating Resin E 4011 LP 1006 70 50 30 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 Aging Time (days) Aging Performance: comparison between conventional systems & new developed products shows excellent Bond Strength 17
Value for Hyundai Motor Company Herberts Electrical // UV - Process State of The Art Impregnating Technology What s so special about Electrical-UV? most environmental-friendly impregnating-technology amount of resin usage and impregnating quality can be controlled exactly from average to maximum draining losses and evaporation losses are minimized combined with low emission products and high pre-heat temperatures emissions from 1-3 % only are possible 18
Value for Hyundai Motor Company Herberts Electrical // UV - Process (for Impregnation of Stators) 100 80 Costs (%) 60 40 20 0 Plant Energy Processing Time Typical Dip & Bake Process Cleaning Reduction VOC Electrical / UV Process 19
Purpose & Users of Core Sheet Varnishes Purpose: electrical insulation of each metal sheet to another for construction of magnetizable cores in electrical machines Users: Producers of electrical steel and big-sized generators, worldwide VOLTATEX : DuPont brand name for the family of highly sophisticated core sheet varnishes 20
Value for Hyundai Motor Company VOLTATEX E 1175W: Welding Bonding Insulation 5 4 3 2 1 0 Punching Overcoatability Properties 5 excellent 0 not applicable Annealing Corrosion Burnoff repair Pressure Stability DuPont has developed the self-bonding varnish VOLTATEX E 1175W, a waterborne system with excellent insulation and processing characteristics. These advantages make VOLTATEX E 1175W the ideal insulation system for high performance applications, e.g. advanced HEV- Motors. 21
Benefits when using Core Sheet Varnish Voltatex E 1175W Functional self-bonding varnish to hold a stack of electrical steel sheets together and form a solid core Exact stack dimensions and flexibility in design homogeneous core stacking and no interlaminar cross-circuit in the stack No squeezing effect Excellent surface insulation High bond strength Waterborne system, environment-friendly, innovative varnish systems 22
Product Range VOLTATEX : The Family of Core Sheet Varnishes VOLTATEX E 1120: the innovative Titanate based C5 insulation system with high heat resistance as an environmental-friendly alternative to delicate chromium based varnishes (complies with the stringent RoHS standards) VOLTATEX E 1175W: self-bonding varnish system based on epoxy resins allowing a very efficient fixing technology for core sheet stacks VOLTATEX E 1151: pigmented and filled core sheet varnishes engineered especially for the advanced generator industry VOLTATEX E 1153: unfilled systems with excellent punching performance and outstanding resistance against mechanical and chemical influences => all VOLTATEX systems are waterborne systems 23
From Electrical Steel To Electrical Machines yellow Requirements of Core Sheet Varnishes Electrical Steel Application Punching Compound Technologies Stacking Welding Al die casting Bonding Annealing Electrical Machines Insulation Corrosion Motor Transformer Generator 24
DuPont Performance Coatings Electrical Insulation Systems Impregnating Materials Wire Enamels Core Sheet Varnishes 25