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Adhesives for E-Motors Multiple bonds in e-motors
Adhesives for E-Motors Mul
tiple
bon
ds
in e
-mot
ors
CR = Casting ResinDB = Dual BondingGE = General EncapsulantHT = High Temperature
DELO’s adhesives for …
FAST PROCESSES (LIGHT FIXATION < 10 S)
DELO-ML DB, DELO DUALBOND
HIGHLY RELIABLE CASTING
DELO-DUOPOX CR, DELO MONOPOX GE
HIGH TOLERANCES, GAP-FILLING
DELO-DUOPOX, DELO-PUR
HIGH-TEMPERATURE APPLICATIONS (+220 °C)
DELO MONOPOX HT
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Bonding the stator to the housing
Magnet bonding
Shaft bonding
Adhesives for e-motorsWhen manufacturing modern e-motors, it is essential to improve the efficiency, for example by minimizing the air gap between magnet and winding. Since conventional methods, such as mechanical clamping or wrapping reach their limits due to high tolerances, bonding is the solution.
The requirements imposed on the e-motor components to be joined (and therefore also on the adhesives used) are high. In this respect, recurring buzz words such as temperature-resistant, resistant to chemicals, gap-filling, impact-resistant and tension-equalizing are often used. The adhesives specially developed for e-motors have precisely these properties.
The overview on the left shows a selection of DELO adhesives used in specific e-motor applications according to their properties.
HEAT CURINGROOM TEMPERATURE CURING
GAP-FILLING > 250 µm
IMPACT- RESISTANT
HIGH TEMPERATURE STABILITY ≥ +200 °C
FAST FIXATION
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Bonding magnets to rotors
Bonding buried magnets into rotors
Magnet bondingMore and more e-motor magnets are bonded as adhesives have several property and process advantages over conventional mechanical joints:
� Tolerance compensation � Evenly distributed stress � Easy to automate � Reduced vibration noise � Good corrosion protection � No component damage during joining
Bonding magnets into housings
Your benefits � High temperature stability up to +220 °C � Excellent chemical resistance � Good gap filling � Fast light fixation (< 10 s) � Tension-equalizing
DELO-ML DB135 DB180 DB154
Dual curing anaerobic / light
Fixation in less than 10 s with DELOLUX 20 or DELOLUX 80
DELO-ML 5327
Anaerobic curing
Temperature resistance up to +200 °C
Fast fixation with activator
DELO-DUOPOX AD840 DELO-PUR 9694
2C adhesives
Peel resistance
DELO MONOPOX MG063
1C epoxy
Fast induction curing
DELO MONOPOX HT282
1C epoxy
Impact resistance
DELO MONOPOX AD298
1C epoxy
High run resistance during curing
DELO MONOPOX HT281
1C epoxy
High dielectric strength
AD = ADhesive DB = Dual Bonding HT = High Temperature MG = MONOPOX Gießharz [casting resin]
Find the right adhesive …
HEAT CURINGROOM TEMPERATURE CURING
HIGH TEMPERATURE STABILITY ≥ +200 °C
GAP-FILLING > 250 µm
IMPACT- RESISTANT
FAST FIXATION
Find the right adhesive …
AD = ADhesive DB = Dual Bonding UB = Universal Bonding 4
Bonding the stator laminations to the housing is more advantageous than conventionally joining these components by pressing or shrinking:
� Equalize tensions between the stator and housing with dissimilar CTEs
� Heat not mandatory � More cost-efficient production � Improved acoustics by damping properties
of the adhesive � Larger production tolerances possible
Brushless DC motor © ebm-papst
Bond stator to housingYour benefits � High temperature stability up to +200 °C � Fast light fixation for short cycle times
(DELO-ML DB) � Accelerated curing with activator (DELO-ML) � Curing at room temperature
(except for DELO MONOPOX)
DELO-DUOPOX AD840
2C epoxy
Peel resistance
DELO MONOPOX AD066
1C epoxy
Good flow behavior
DELO-ML DB135DB180DB154
Dual curing anaerobic / light
Fixation in less than 10 s with DELOLUX 80
DELO-ML 5327
Anaerobic curing
Fast fixation with activator
DELO-ML UB160
Anaerobic curing
Fast fixation with activator
AD = ADhesive DB = Dual Bonding UB = Universal Bonding
HEAT CURINGROOM TEMPERATURE CURING
GAP-FILLING > 250 µm
IMPACT- RESISTANT
HIGH TEMPERATURE STABILITY ≥ +200 °C
FAST FIXATION
Find the right adhesive …
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Similar to shaft-to-hub bonds in mechanical engineering, the shaft of e-motors is bonded to the bearing, rotor package and commutator. Anaerobic, low-viscous adhesives are preferred as the bonding gap is narrower due to very low tolerances. Adhesive bonds have the following advantages over classical form- or force-closed joints:
� Low component production costs � Easy to automate � No clearance, no slip � No friction or contact corrosion
Shaft bondingYour benefits � Fast fixation by activator or light (DELO-ML) � Curing at room temperature
(DELO-ML, DELO-DUOPOX) � Very high temperature stability up to +220 °C
(DELO MONOPOX)
Collector to shaft with DELOMONOPOX HT281
© metabo
DELO MONOPOX AD066
1C epoxy
Good flow behavior
DELO MONOPOX HT282
1C epoxy
Temperature stability up to +220 °C
Impact resistance
DELO MONOPOX HT281
1C epoxy
Temperature stability up to +220 °C
High dielectric strength
DELO-ML DB135DB154
Dual curing anaerobic / light
Fixation in less than 10 s with DELOLUX 80
DELO-ML 5327
Anaerobic curing
Temperature resistance up to +200 °C
Fast fixation with activator
DELO-DUOPOX AD840
2C epoxy
Peel resistance
AD = ADhesive DB = Dual Bonding HT = High Temperature
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Casting compounds are used in e-motors to protect sensitive components from humidity, chemicals or mechanical stress. Therefore, DELO’s adhesives are used in the automotive industry due to these special challenges. Possible applications:
� Secure coil wires against vibration � Cover soldered and welded contacts to protect them
against corrosion � Partial protection of windings from abrasive
substances � Stator casting
Cast & coverYour benefits � Excellent resistance to aggressive substances
(e. g. gear oil) � Outstanding thermal resistance and low thermal
expansion combine to minimize tensions between cast and component
� Very fast fixation or curing by light
Motor for power toolsStator of an automotive
drive module
Protection of the stator windings
Partial protection of the windings
Contact protection
DELO MONOPOX GE727
1C casting resinCTE 11 ppm / K
DELO- DUOPOX CR716
2C casting resinCTE 37 ppm / K
DELO MONOPOX GE785
1C casting resinHigh run resistanceCTE 22 ppm / K
DELO DUALBOND AD761
Dual curing light / heatIrradiation time of 30 s or less with DELOLUX 80
DELO DUALBOND AD465
Dual curing light / heatFast light curing in less than 4 s with DELOLUX 80
DELO-DUOPOX CR844
2C casting resinCuring can be accelerated by heat
DELO KATIOBOND 45952
Light-activatedIrradiation time of 60 s or less with DELOLUX 80
DELO DUALBOND AD4950
Dual curing light / humidityFast light curing in less than 10 s with DELOLUX 80
AD = ADhesive CR = Casting Resin GE = General Encapsulant
HEAT CURINGROOM TEMPERATURE CURING
HIGH RELIABILITY LOW CTE FAST
FIXATIONHIGH FLEXIBILITY
Find the right adhesive …
Encapsulants
with High Reliability
Chi
p-on
-boa
rd e
ncap
sula
tion
– R
AFI
Elte
c G
mbH
DELO’s light-curing adhesives enable the reliable sealing of microswitches, relays and connectors, fi xing of electronic components, and bonding of housing parts. Applications in the automotive industry in particular require fast bonding processes combining short cycle time with reliable process control. DELO’s light-curing
adhesives are excellent for this purpose: Fast curing within seconds by exposure to light (“curing on demand”) enables immediate in-line quality control. This is how component defects can be detected promptly and necessary remedial actions can be taken, saving time and cost.
Microswitches: Pin sealing, bonding of housing, sealing of switch button
Connectors: Reliable
pin sealing
Fast sealing of electronic components within just secondscomponents within just seconds
Relays: Pin casting – the adhesive fl ows into the cavity
DELO-PHOTOBOND | DELO-DUALBOND acrylates1C Fast light fi xation within seconds (immediate fi nal strength)
Highly fl exible and tension-equalizing Curing in shadowed areas (by heat or humidity)DELO-PHOTOBONDDELO-DUALBONDGE4009
GE4906GE4707
Viscosity [mPas]
1,6002,200
1,500
Curing
UV-VIS UV-VIS / humidity UV-VIS / heat
Minimum curing time [s]9
77
Elongation at tear [%]500
500460
Temperature resistance
– 40 to +150 °CDELO-KATIOBOND | DELO-DUALBOND epoxies1C Fast light fi xation within seconds Can be preactivated 1) (for opaque components)
Curing in shadowed areas (by heat) Hard or fl exible compositeDELO-KATIOBONDDELO-DUALBOND4578 KB554 AD761 GE731
Viscosity [mPas]12,400 1,500 11,000 17,000
Curing
UV-VIS 1)UV-VIS 1)
UV-VIS / heat UV-VIS / heat
Minimum irradiation time [s]15
2410
6
Elongation at tear [%]3
4584
98
Temperature resistance
– 40 to +150 °C– 40 to +180 °C
AD = ADhesive GE = General Encapsulant KB = KatioBond
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ADDITIONAL BONDING TASKS A COMPREHENSIVE OVERVIEW
of pretreatment methods can be found in the “BOND it – Reference Book on Bonding Technology”.
Lab expertiseDELO is a technology leader, generating about 30 percent of its sales revenues with products developed in the last three years. In addition, 15 percent of revenues are invested in the research and development of adhesives and associated equipment.
These statistics are a result of the enormous laboratory expertise in the Windach headquarters: Comprehensive
analytics and lab tests make it possible to find the right adhesive for every bonding task, including those in e-motor bonding.
In addition to chemical-physical characterization of adhesives, life cycle tests, application-specific test methods and process simulations are performed.
� Encapsulants with High Reliability
� Sealing Electronic Components
www.youtube.com/ DELOadhesives
E-MOTOR PROCESS VIDEO
IDEA DESIGN PROTOTYPE INTEGRATION PRODUCTION ONGOING SUPPORT
CONTACT
Dispensing Curing ConsultingAdhesives
The data and information provided are based on tests performed under laboratory conditions. Reliable information about the behavior of the product under practical conditions and its suitability for a specific purpose cannot be concluded from this. It is the user’s responsibility to test the suitability of the product for the intended purpose by considering all specific requirements. Type, physical and chemical properties of the materials to be processed with the product, as well as all actual influences occurring during transport, storage, processing and use, may cause deviations in the behavior of the product compared to its behavior under laboratory conditions. All data provided are typical average values or uniquely determined parameters measured under laboratory conditions. The data and information provided are therefore no guarantee for specific product properties or the suitability of the product for a specific purpose. Nothing contained herein shall be construed to indicate the non-existence of any relevant patents or to constitute a permission, encouragement or recommendation to practice any development covered by any patents, without permission of the owner of this patent. All products provided by DELO are subject to DELO’s General Terms of Business. Verbal ancillary agreements are deemed not to exist.
© DELO – This brochure including any and all parts is protected by copyright. Any use not expressly permitted by the Urheberrechtsgesetz (German Copyright Act) shall require DELO’s written consent. This shall apply without limitation to reproductions, duplications, disseminations, adaptations, trans lations and microfilms as well as to the recording, processing, duplication and/or dissemination by electronic means.
Industrial Adhesives Singapore Phone +65 6807 0800 [email protected] www.DELO-adhesives.com/en
Industrial Adhesives Malaysia · Kuala Lumpur Phone +65 6807 0800 [email protected] www.DELO-adhesives.com/en
Headquarters
Industrial AdhesivesGermany · Windach / Munich Phone +49 8193 9900-0 [email protected] www.DELO.de
Industrial Adhesives China · Shanghai Phone +86 21 2898 6569 [email protected] www.DELO-adhesives.com/cn
Industrial Adhesives South Korea · Seoul Phone +82 2 2190 3727 [email protected] www.DELO-adhesives.com/en
Industrial Adhesives USA · Sudbury / Boston, MA Phone +1 978 254 5275 [email protected] www.DELO-adhesives.com/us
Industrial Adhesives Taiwan · Taipei Phone +886 2 6639 8248 [email protected] www.DELO-adhesives.com/cn
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