Projects
Projects: Custom Search |
||
| Reference Number | UKRI642 | |
| Title | High performance polymer insulating coatings for high-voltage e-motors | |
| Status | Started | |
| Energy Categories | Energy Efficiency (Transport) 70%; Other Power and Storage Technologies (Electricity transmission and distribution) 30%; |
|
| Research Types | Basic and strategic applied research 100% | |
| Science and Technology Fields | ENGINEERING AND TECHNOLOGY (Electrical and Electronic Engineering) 30%; ENGINEERING AND TECHNOLOGY (Mechanical, Aeronautical and Manufacturing Engineering) 70%; |
|
| UKERC Cross Cutting Characterisation | Not Cross-cutting 100% | |
| Principal Investigator |
Nan Yi University of Exeter |
|
| Award Type | Standard | |
| Funding Source | EPSRC | |
| Start Date | 01 October 2025 | |
| End Date | 01 April 2027 | |
| Duration | 18 months | |
| Total Grant Value | £256,643 | |
| Industrial Sectors | Unknown | |
| Region | South West | |
| Programme | NC : Engineering | |
| Investigators | Principal Investigator | Nan Yi , University of Exeter |
| Other Investigator | Oana Ghita , University of Exeter |
|
| Web Site | ||
| Objectives | ||
| Abstract | As the global economy shifts towards low-carbon solutions, the electrification of transport has increased the demand for electric motors with maximised power and torque density, and reduced weight to enhance efficiency. Critical to this development are advanced materials for electrical insulation, such as slot liners and coatings, which are essential to e-motors. The push for faster vehicle charging speed requires higher system voltages, introducing significant challenges for insulation materials, especially as 800 V technology becomes mainstream. These materials must withstand high temperatures, electrical stresses, and exposure to cooling fluids while maintaining high breakdown voltages (BDV) and partial discharge inception voltages (PDIV), ensuring long-term reliability. Traditional high-temperature insulation materials, such as ceramics and polyimides, present significant limitations including prone to crack, complex processing conditions, and limited recyclability. In contrast, polyaryletherketones (PAEKs) have emerged as promising candidates for insulating electric wires and hairpins in e-motors due to its non-polar nature. PAEKs offer exceptional thermal endurance and chemical resistance, enhancing the reliability of e-motors, particularly in high-voltage systems. Moreover, PAEKs are lightweight, recyclable, offering less hazardous and more energy efficient manufacturing processes compared to ceramics and polyimides. Despite these advantages, the underlying mechanisms of how these semi-crystalline polymers behave under high-voltage conditions are currently less understood. The aim of this research is to fundamentally understand the development of the microstructure of PAEKs during wire processing and wire forming, and their subsequent impact on dielectric properties such as BDV and PDIV. To achieve this, the first objective will be conducting a systematic investigation to benchmark detailed correlations between crystallinity, crystal morphology, and amorphous composition with BDV and PDIV under both ambient and elevated temperatures. The second and third objectives will be analysing the complex microstructures presented in commercial wires, as well as the mechanical conditions during the wire forming process. Predictive models will be developed to forecast their insulation performance. We will replicate the thermal and mechanical conditions observed in industrial wire processing to establish direct links between processing and forming parameters and the resulting microstructure. The knowledge obtained from these investigations will enable us to make reliable predictions and optimisation strategies of the final insulation quality, providing superior breakdown voltage strength and minimal discharge occurrences. This project will advance our fundamental understanding of the impact of microstructure on the dielectric properties and electrical failure mechanisms of PAEKs under high-voltage conditions. The collaboration with the Winding Centre of Excellence (WCE) at the HVMC will provide direct access to both discrete and continuous hairpin winding facilities, enabling in-process testing of electrical, thermal, and mechanical properties. This collaboration is crucial for optimising the design and manufacturing processes of PAEK-coated wires, ultimately contributing to the development of more efficient and reliable e-motors. The results from this project will facilitate the development of tailored PAEK grades for e-motor applications, optimising wire production and forming processes. This knowledge will accelerate innovation cycles, providing tools for OEMs and tier suppliers to rapidly assess and address their performance requirements. It will enable materials and e-machine companies to explore new design approaches with thinner coatings, enhancing their ability to meet evolving industry standards and performance needs in transport electrification. The project’s outcomes will have broader applications extending beyond automotive e-motors to include aerospace and marine e-motors, and cables and power transmission systems that also endure high electrical stresses and temperatures | |
| Data | No related datasets |
|
| Projects | No related projects |
|
| Publications | No related publications |
|
| Added to Database | 07/01/26 | |
