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Motor Technology

New thermally conductive casting resin offers power and range boost for EVs

Wesley DoyleBy Wesley DoyleJanuary 24, 20232 Mins Read
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Lambdapox causes the stator winding to quickly transfer its heat to the cooling jacket

It’s not only energy that is generated buy an e-motor, heat is a by-product too, and sometimes quite a lot of it. In demanding applications, excess heat in motor electronics can cause the power to be throttled or even shut down completely. Using a static solid cooling system can protect an electric motor from overheating without losing power, and this can be achieved by using a thermally conductive casting resin as a heat transfer medium.

Inventor Uwe Köhler began developing thermally conductive casting resins as far back as the 1990s and the result is Lambdapox, an innovative product from the start-up Lambda Resins. The company is a joint venture between the Köhler and the Nagel Group from Nürtingen, Germany, which has production lines for electric motor stators through its group company Gehring Technologies.

Lambdapox is a resin capable of thermally stabilizing e-motors and thus enabling continuous operations at a high level, reliably, effectively and without a great technical effort. To achieve this, the stator winding of the motor is cast with the resin in a vacuum process, resulting in the heat flowing into the surrounding cooling jacket much faster, negating the issue of heat build-up in the winding.
Lambdapox easily withstands the heat shock test from minus 40 to over 180°C. “Our casting resin causes a reduction in temperatures in the winding head,” says Köhler, “Depending on the configuration, the motors achieve up to 50% higher continuous power at the same thermal load.”

The cast resin is suitable for all high-performance motors, but especially EVs.  The focus can be either to maximise performance, or to minimise space requirements while keeping performance unchanged. The former enables performance-enhanced variants of an existing engine without the need for a new development. The latter leads to a less expensive unit and a lower Co² footprint per kW of engine power. For EVs, lower engine heating results in higher efficiency, leading to increased range.

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Wesley Doyle

Wesley Doyle is editor of Electric & Hybrid Vehicle Technology International and Stadia. He has over two-decades experience in publishing during which time he has worked at some of the UK’s leading consumer magazine titles in the health and fitness and sport sectors. Wesley is also passionate about cycling and interested in alternative technologies, particularly in transportation, to achieve net zero.

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