How Ampact™ drives sustainable hairpin wire solutions for 800V applications

Battery electric vehicles (BEV) offer consumers a green alternative to their gasoline-powered counterparts. However, to meet increasingly strict sustainability standards while pushing performance, OEMs need to rethink the stator design. At Bekaert, we are one mile ahead. Because with Ampact™, our PEEK coated copper magnet wire, we provide you with a sustainable solution designed for 800V applications and beyond. And we’ve got the life-cycle assessment to prove it.

As electric vehicles become increasingly popular, OEMs are being challenged to push their performance to 800V and beyond. Hairpin and continuous winding technology ticks that box: offering increased power density, enhanced heat dissipation, and improved efficiency regarding automation.

This is also why we decided to perform a life-cycle assessment (LCA) of Ampact™, our innovative PEEK insulated copper magnet wire. Together with specialized institutes, we conducted a comprehensive analysis (ISO 14040/44) to examine its environmental impact from cradle to gate.

As defined by the European Environment Agency, the key steps of such an LCA are:

identifying raw materials, energy consumption, emissions, and waste generation;
evaluating their environmental impact;
and defining strategies for mitigating these effects.

A PEEK into sustainable winding wire technology

Based on this life-cycle analysis, Ampact™'s long term ambitions can reduce emission down to approximately 2.5 kg CO2 per kilo hairpin wire produced: a significant reduction compared to similar products available today. This can be achieved by utilising raw materials with state-of-the-art low-carbon emission (like the copper wire rod and polymer insulation coating) in combination with coating processes with higher energy efficiency (e.g. extrusion). Here are some of the most significant benefits gained throughout the various stages of the life cycle.

Eliminate harmful emissions

Enamel coating refers to a layer-by-layer coating depositing whereby high-quality copper wire is repeatedly dipped into a solvent-containing polymer solution. In addition to being energy-intensive, this process gives rise to solvent evaporations, resulting finally in the potential emission of NOx gases. This is particularly problematic given the fact that these are up to 200 times more harmful than CO2 emissions.

PEEK coating, by contrast, implements a single-step extrusion process. In other words, the full layer is applied in one go without the use of harmful solvents. This has two clear advantages: firstly, no NOx will be emitted. Secondly, the production process requires up to 5 times less energy.

Fewer raw materials, more power

In addition to being solvent-free, single-layer PEEK coating is defect-free and facilitates sharper and shorter bends. This means you could benefit from material and weight savings by reducing the motor in size (without compromising the energy output); or boost the power of your stator within the same dimensions. And bonus: there’s still a huge potential for scrap reduction during the process of hairpin bending.

Built to last in 800V environments

Next, the type of coating plays a key role in the longevity of your winding wire. Whereas the lifespan of the brittle PAI enamel coating can more easily be affected by the harsh 800V environments, PEEK coating is built for better electrical insulation and higher maximum operating temperatures (240-260 °C).

Additionally, the ability to use thinner insulation layers optimizes heat dissipation – and reduces the need for cooling –, without compromising the chemical resistance to cooling fluids. In other words: the coating, and therefore your stator, will last longer.

Recyclable thermoplastics

Finally, at the end of life, a PEEK insulated hairpin wire can easily be recycled. First, the thermoplastic insulation layer is melted off. Next, the copper wire can be re-melted as well. All materials can thus be given a second life.

This is in stark contrast to enamel coatings. Since the primary insulation layer consists of thermoset materials, they need to be burned off before the copper underneath can be separated and recycled. This gives rise to additional CO2 and NOx emissions.

Conclusion

As the demand for high-voltage applications increases (≥800V), the PEEK coated Ampact™ hairpin wire champions a ground-breaking solution that pairs superior performance with sustainable innovation.

A commitment confirmed by a meticulous life-cycle assessment (LCA) in collaboration with specialized partners. Comparing PEEK coating to enamel PAI coatings, its key findings include:

Significant reduction in greenhouse gas emissions;
Elimination of harmful NOx gases;
Up to 5 times less energy required during production;
Potential for material and weight savings;
Less cooling required or higher peak power output;
And an easily recyclable thermoplastic insulation layer.

In short, with Ampact™ you are setting the course for a cleaner, more responsible future for electric mobility.

About Bekaert’s sustainability ambition

At Bekaert, we are committed to driving a sustainable future for all. Firstly, by achieving carbon neutrality by 2050. An ambitious goal validated by the Science Based Targets initiative (SBTi) as part of the UN Climate Champions’ Race to Zero.

Secondly, we aim to be part of the solution by designing sustainable products and services, and promoting sustainability across the entire value chain.