Case study
Desmodur®-based crosslinking technology beats the heat in solar car’s engine
The Sonnenwagen’s original engine was hindered by the maximum operating temperature of the electrical insulating coating used to cast the electrical wires. This year, the team developed a new and improved engine with a copper coil that is fixed and protected by our Desmodur®-based crosslinking technology.
Case study · October 2, 2019
Enhance the engine to endure high temperatures
For maximum efficiency, especially at the steep slope of the road, Team Sonnenwagen (opens in a new tab) needed to improve the design of the car’s electric motor to withstand higher temperatures. The team needed a coating technology that could create a heat-resistant, rigid casting that would protect the engine’s copper coils.
Improve casting resin’s temperature stability
The resin that keeps the copper windings of the engine together must resist high temperatures. Polyurethane chemistry has limited temperature stability, so we set out to modify our coating system.
New crosslinking technology revs into high gear
We recently developed a coating system that offers outstanding thermal and chemical stability. We deployed this as a casting resin for the coils in the car’s motor. Based on Desmodur® products, our new crosslinking technology significantly increases the coating’s temperature stability. When compared to traditional 2K polyurethane coatings, this technology goes the extra mile in terms of temperature and chemical resistance as well as mechanical stability.
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Higher heat resistance means that we can put more power into the motor and, as a result, accelerate faster.
Enno Dülberg
Motor Engineer, Sonnenwagen Aachen e. V.
Customers are excited about the high temperature stability of the new material, especially within the field of electrical insulation.
Dr. Florian Golling
Lab Head, New Technologies, Covestro
Why crosslinking technology was the right solution for the engine
Mechanical stability:
Offers improved mechanical stability when compared to the previously used cast system.
Chemical resistance:
Provides increased chemical resistance, especially against brake fluids and oil.
High temperature stability:
Features increased temperature stability up to 220 degrees Celsius.
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