Electric Machine Winding Potting for High-Temperature Durability

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Solution Overview

Problem

Existing electric machines for motor vehicles face challenges in achieving high performance and durability under high operating temperatures due to the limitations of conventional potting materials with glass transition temperatures below 200 degrees Celsius.

Innovation Solution

The use of a composite potting material comprising cycloaliphatic epoxy resin and anhydride, optionally with mineral filler, to embed winding subregions, which provides a glass transition temperature above 200 degrees Celsius, ensuring the electric machine can withstand high temperatures without damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional potting materials with glass transition temperature below 200°C are used, then the electric machine can be manufactured with standard materials, but the operational durability and performance deteriorate under high operating temperatures

Engineering Contradiction:

Improveoperational durabilityVSAvoidglass transition temperature

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The patent changes the chemical composition parameters of the potting material by using cycloaliphatic epoxy resin instead of conventional epoxy resin, which raises the glass transition temperature from below 200°C to above 200°C, thereby improving reliability under high temperature operation

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs a composite material system consisting of cycloaliphatic epoxy resin combined with specific curing agents and fillers, creating a potting material with enhanced thermal properties that maintains structural integrity at high operating temperatures

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If conventional potting materials are used, then the manufacturing process remains simple, but thermal expansion increases causing performance degradation

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidthermal expansion

Core Design Contradiction:

Ease of manufactureVSStability of the object's composition

Solution Approach 1:

The patent modifies the material composition to achieve low thermal expansion characteristics while maintaining ease of manufacturing through standard potting processes, using cycloaliphatic epoxy resin which inherently provides better dimensional stability

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The composite potting material enhances the operational durability, performance, and lifetime of the electric machine by maintaining low thermal expansion and high temperature resistance.

Implementation Method 1

provides a glass transition temperature above 200 degrees Celsius, ensuring the electric machine can withstand high temperatures without damage

Methodology Applied

Scientific EffectGlass transition temperature:

Implementation Method 2

maintaining low thermal expansion and high temperature resistance

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 3

high temperature resistance

Methodology Applied

Scientific EffectThermal resistance:

Data Source

PatentUS12573908B2Electric machine for a motor vehicle, use of such an electric machine, and motor vehicle

Publication Date: 2026.03.10 BAYERISCHE MOTOREN WERKE AG

AI summary

An electric machine for a motor vehicle includes at least one winding which has at least one partial region embedded into a casting material. The casting material is a mixture including at least one cycloaliphatic epoxide resin and at least one anhydride.