Magnet Wire Lubricant Composition for Insulation Compatibility
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Solution Overview
Problem
Existing lubricants for electric and hybrid-electric vehicles are not compatible with the insulation coatings of magnet wires in electric motors, leading to degradation and reduced performance over time.
Innovation Solution
A lubricating and cooling fluid system is developed, comprising a detergent system with at least 50 ppm metal and a base oil system with a first lubricating viscosity base oil blended with an ester base oil, where the ester base oil constitutes at least 20 weight percent of the base oil system, and the ratio of metal provided by the detergent system to percent of ester groups in the base oil system is 70 or less.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional lubricant additives (anti-oxidants, detergents, dispersants, anti-wear agents) are used to achieve lubricating performance, then lubricating capability is improved, but compatibility with insulation coatings of electrical wires deteriorates
Solution Approach 1:
The patent removes traditional lubricant additives (anti-oxidants, detergents, dispersants, anti-wear agents, rust inhibitors, metal deactivators, friction modifiers, antifoam agents, seal swell agents, and viscosity index improvers) from the lubricant composition. This extraction eliminates the harmful interaction between these additives and insulation coatings while maintaining lubricating performance through the base oil and ester base oil formulation.
Solution Approach 2:
The patent changes the chemical composition parameters of the lubricant by specifying a formulation consisting of base oil (at least 70 weight percent) and ester base oil (at least 20 weight percent), with explicit exclusion of traditional additives. This parameter change ensures compatibility with insulation coatings while providing adequate lubricating performance for electric motor applications.
2Reliability
If lubricating fluid contains traditional additives package, then lubricating and cooling performance is improved, but electrical conductivity and compatibility with electronic componentry deteriorates
Solution Approach 1:
The patent extracts and eliminates the traditional additives package from the lubricant composition, retaining only the base oil and ester base oil components. This removal resolves the conflict between lubricating performance and compatibility with electronic componentry, as the simplified formulation does not contain substances that would degrade insulation coatings or interfere with electrical conductivity.
3Reliability
If high concentration of traditional lubricant additives is used, then anti-wear and friction reduction capability is improved, but thermal conductivity and cooling performance deteriorates
Solution Approach 1:
The patent removes traditional anti-wear agents and friction modifiers from the formulation, achieving adequate anti-wear capability through the base oil and ester base oil combination without compromising cooling performance. The absence of these additives ensures that thermal conductivity is not degraded.
Solution Approach 2:
The patent creates a composite lubricant system combining base oil and ester base oil in specific proportions (base oil at least 70 weight percent, ester base oil at least 20 weight percent). This composite formulation provides both lubricating and cooling functions without the need for traditional additives that would interfere with thermal conductivity.
Data Source
Figure 1
AI summary
The present disclosure relates to a driveline for an electric or hybrid-electric vehicle including an electric motor with an insulated magnet wire and a lubricating and cooling fluid configured to maintain the durability of the magnet wire.