Views: 12 Author: Site Editor Publish Time: 2024-12-09 Origin: Site
With the rapid advancement of new energy vehicle technologies, high-voltage platforms exceeding 800V have become the mainstream choice for drive motors. These platforms provide fast and efficient charging capabilities and an exceptional driving experience. However, traditional thermoset PI (polyimide) materials are prone to stress concentration during bending or wave winding processes, which can lead to cracking risks and pose serious safety threats to the vehicle.
Against this backdrop, flat wire motors have emerged, and PEEK, with its unique advantages, has quickly become the preferred material for drive motors. PEEK flat wires boast high slot-fill ratios, compact structures, excellent toughness, superior bending resistance, outstanding electrical properties, and solvent resistance. These characteristics enable them to easily meet the challenges posed by high-voltage environments.
PEEK, as an innovative material for flat wire motor technology, plays a key role in enhancing motor insulation performance and power density with its exceptional resistance to high temperatures, wear, corona discharge, and fatigue. Under 800V high-voltage fast charging conditions, PEEK flat wires not only meet high-voltage and high PDIV (Partial Discharge Inception Voltage) requirements but also maximize conductor density through single-layer extrusion technology, further advancing the performance of drive motors.
The advantages of PEEK materials are not limited to electrical performance; their thermal performance is equally impressive. The rectangular cross-sectional design of PEEK flat wires optimizes internal voids, increasing the contact area between conductors and significantly enhancing heat conduction efficiency. Combined with oil-spray cooling technology, the winding temperature of PEEK flat wire motors is significantly reduced, ensuring stable operation under extreme conditions.
Additionally, PEEK materials demonstrate remarkable capabilities in processability and environmental friendliness. Their excellent flowability in the molten state and mechanical and dimensional stability after solidification enable one-step extrusion molding of PEEK flat wires, reducing processing difficulty and cost. Furthermore, the non-toxic, pollution-free nature of PEEK materials, along with the complete recyclability of waste during processing, aligns with green production principles, further reducing production costs and achieving a win-win for economic and environmental benefits.
To meet the specific demands of flat wire motors, Junhua has independently developed PEEK5600FG25 granules. This material is specifically designed for flat wire motors. Compared to standard PEEK materials for cables, PEEK5600FG25 exhibits better adhesion, allowing for tighter bonding with conductors. Its notable features include:
PEEK5600FG25 offers higher strength and improved toughness. Its molecular backbone incorporates both flexible ether groups and rigid benzene rings, enabling the material to maintain structural integrity under mechanical stress or vibration, minimizing risks of breakage or deformation. This provides a robust safety assurance for the entire new energy vehicle system.
PEEK flat wires exhibit excellent high-temperature resistance, capable of continuous operation in environments up to 260°C. In contrast, PI (polyimide) enameled wires typically operate within a range of 80-200°C. This ensures better stability and longer service life for PEEK flat wires in high-temperature conditions.
PEEK5600FG25 has a dielectric constant of only 3.0, slightly higher than that of PE (polyethylene) and fluoroplastics but significantly lower than PVC. As shown in the comparison curve below, general PEEK polymers exhibit excellent electrical properties across a frequency range of 10⁹ Hz. PEEK polymers maintain these superior insulating properties across a wide temperature and frequency range. As seen in the figure, PEEK material exhibits low tanδ losses below 140°C.
With its outstanding performance and extensive application potential, PEEK has become the ideal material for flat wire motors in 800V high-voltage platforms. As the electric vehicle market continues to expand and technological iterations accelerate, PEEK materials will play an increasingly important role in advancing EV charging speed and performance optimization, contributing to the green development of the new energy vehicle industry.