Discover Ampact™ at Coiltech Deutschland 2024

High-voltage drivetrains demand higher chemical, thermal, electrical, and mechanical capacities of the magnet wire used in the stator of the e-motor. To meet these new requirements and extend the lifetime of the copper winding wire, we replaced the traditional insulation with an innovative polyetheretherketone or PEEK-coating. The thin coating (100-200µm on average) is applied in one extrusion step using a single layer, which helps you save plenty of time during the production process. Additionally, the extruded coating …

• increases the fill factor which boosts powertrain performance and efficiency
• has higher insulation power (= less corona sensitive)
• doesn’t crack when bent in extreme positions
  
• allows for a defect-free usage in mission-critical 800V-applications 

We help you shift to the next gear of both innovation and sustainability. Ampact™  winding wire is built not only to perform in extreme motor environments. Also during the production and end-of-life recycle process it has strong credentials.

Firstly, unlike the multi-step application process of conventional enamel coatings, the PEEK coating is applied in one single step and therefore significantly more energy-efficient. 

Next, the coating process is solvent-free. By eliminating harmful solvents, we put the brakes on NOx gasses associated with enamel coatings. PEEK coating also offers excellent end-of-life recyclability thanks to its thermoplastic characteristics. Additionally, because of PEEK's higher insulation power you need less insulation material. All of this contributes towards reducing the total carbon footprint.

Without affecting the wire's conductivity, Ampact™ PEEK-insulated magnet wire allows you to make sharper and shorter bends which saves space. Because of the high insulation power of the PEEK-coating, the wire thickness can be made thinner. This not only saves on the cost of copper, but it also allows you to make the stator smaller and lighter which in turn leads to lower cost. 

So, as an OEM you can have the best of both worlds:

• Either you build the same size stator (equal overall dimensions) and you will have more performant engines.
• Or you build equally performant engines that have smaller stators (smaller overall dimensions and smaller copper amount). Due to the 800V use, the equally performant engines (power output that is) can still be more efficient due to lower energy losses.